Light emitting, photovoltaic or other electronic apparatus and system

ABSTRACT

The present invention provides an electronic apparatus, such as a lighting device comprised of light emitting diodes (LEDs) or a power generating apparatus comprising photovoltaic diodes, which may be created through a printing process, using a semiconductor or other substrate particle ink or suspension and using a lens particle ink or suspension. An exemplary apparatus comprises a base; at least one first conductor; a plurality of substantially spherical or optically resonant diodes coupled to the at least one first conductor; at least one second conductor coupled to the plurality of diodes; and a plurality of substantially spherical lenses suspended in a polymer attached or deposited over the diodes. The lenses and the suspending polymer have different indices of refraction. In some embodiments, the lenses and diodes have a ratio of mean diameters or lengths between about 10:1 and 2:1. The diodes may be LEDs or photovoltaic diodes, and in some embodiments, have a junction formed at least partially as a hemispherical shell or cap.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of and claims priority toU.S. patent application Ser. No. 11/756,616, filed May 31, 2007,inventors William Johnstone Ray et al., entitled “Method ofManufacturing Addressable and Static Electronic Displays”, which iscommonly assigned herewith, the entire contents of which areincorporated herein by reference with the same full force and effect asif set forth in their entirety herein, and with priority claimed for allcommonly disclosed subject matter.

This application also is a continuation-in-part of and claims priorityto U.S. patent application Ser. No. 11/756,619, filed May 31, 2007 nowU.S. Pat. No. 7,972,031, inventors William Johnstone Ray et al.,entitled “Addressable or Static Light Emitting or Electronic Apparatus”,which is commonly assigned herewith, the entire contents of which areincorporated herein by reference with the same full force and effect asif set forth in their entirety herein, and with priority claimed for allcommonly disclosed subject matter.

This application also is a continuation-in-part of and claims priorityto U.S. patent application Ser. No. 12/560,340, filed Sep. 15, 2009concurrently herewith, inventors William Johnstone Ray et al., entitled“Light Emitting, Photovoltaic Or Other Electronic Apparatus and System”,which is commonly assigned herewith, the entire contents of which areincorporated herein by reference with the same full force and effect asif set forth in their entirety herein, and with priority claimed for allcommonly disclosed subject matter.

This application also is a continuation-in-part of and claims priorityto U.S. patent application Ser. No. 12/560,355, filed Sep. 15, 2009concurrently herewith, inventors William Johnstone Ray et al., entitled“Method Of Manufacturing A Light Emitting, Photovoltaic Or OtherElectronic Apparatus and System”, which is commonly assigned herewith,the entire contents of which are incorporated herein by reference withthe same full force and effect as if set forth in their entirety herein,and with priority claimed for all commonly disclosed subject matter.

This application also is a continuation-in-part of and claims priorityto U.S. patent application Ser. No. 12/560,364, filed Sep. 15, 2009concurrently herewith, inventors William Johnstone Ray et al., entitled“Method Of Manufacturing A Light Emitting, Photovoltaic Or OtherElectronic Apparatus and System”, which is commonly assigned herewith,the entire contents of which are incorporated herein by reference withthe same full force and effect as if set forth in their entirety herein,and with priority claimed for all commonly disclosed subject matter.

This application also is a continuation-in-part of and claims priorityto U.S. patent application Ser. No. 12/560,371, filed Sep. 15, 2009concurrently herewith, now U.S. Pat. No. 8,133,768, inventors WilliamJohnstone Ray et al., entitled “Method Of Manufacturing A LightEmitting, Photovoltaic Or Other Electronic Apparatus and System”, whichis commonly assigned herewith, the entire contents of which areincorporated herein by reference with the same full force and effect asif set forth in their entirety herein, and with priority claimed for allcommonly disclosed subject matter.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with Government support under contractSAA8-094274 awarded by NASA. The government has certain rights in thisinvention.

FIELD OF THE INVENTION

The present invention in general is related to light emitting andphotovoltaic technology and, in particular, is related to lightemitting, photovoltaic or other electronic apparatus and system andmethods of manufacturing a light emitting, photovoltaic or otherelectronic apparatus or system.

BACKGROUND OF THE INVENTION

Lighting devices having light emitting diodes (“LEDs”) have typicallyrequired creating the LEDs on a semiconductor wafer using integratedcircuit process steps. The wafer is then divided, individual LEDs areplaced in a reflective casing, and bonding wires are individuallyattached to each LED. This is a time consuming, labor intensive andexpensive process, resulting in LED-based lighting devices which aregenerally too expensive for many consumer applications.

Similarly, energy generating devices such as photovoltaic panels havealso typically required creating the photovoltaic diodes on asemiconductor wafer or other substrates using integrated circuit processsteps. The resulting wafers or other substrates are then packaged andassembled to create the photovoltaic panels. This is also a timeconsuming, labor intensive and expensive process, resulting inphotovoltaic devices which are also too expensive for widespread usewithout being subsidized or without other governmental incentives.

Other methods of manufacturing photovoltaic devices are also beingdeveloped. For example, Hammerbacher et al. U.S. Patent Publication No.2008/0289688, published Nov. 27, 2008, entitled “Photovoltaic ApparatusIncluding Spherical Semiconducting Particles”, and Hamakawa et al. U.S.Pat. No. 6,706,959, issued Mar. 16, 2004 and entitled “PhotovoltaicApparatus and Mass Producing Apparatus for Mass Producing SphericalSemiconducting Particles” disclose a method which initially usesspherical diodes having a pn junction formed about the entire sphere,but then introduce manufacturing problems by requiring correspondingmicromachining of each individual diode to remove a substantial sectionof the sphere and its pn junction, to form a recess into an inner, coreportion. What was initially a spherical diode is micromachined to becomesignificantly or appreciably aspherical, to create a substantially flat,recessed side having an exposed inner, core portion, in order to accesseither an n-type (or equivalently, N-type) or p-type (or equivalently,P-type) interior substrate portion of the diode for bonding to anelectrode. Once micromachined, the individual aspherical diodes must beproperly oriented, individually placed, and bonded to conductors at boththe exterior and the recessed interior parts of the diode to produce aresulting device. Again, this is also a time consuming, labor intensiveand expensive process, with corresponding difficulties for generatingwidespread use.

Another method of manufacturing photovoltaic devices, disclosed in EbertU.S. Pat. No. 4,638,110, issued Jan. 20, 1987, entitled “Methods andApparatus Relating to Photovoltaic Semiconductor Devices”, utilizes aclear, solid sheet having an array of curvatures on a first side of theclear solid sheet, to form an integrally formed array of abutting solarconcentrating lenses with a single index of refraction. The lens panelfurther has a flat, second side coupled and fixed to a prefabricatedpanel, with the prefabricated panel having solid conducting layersseparated by an insulating layer. In this method, a laser is steppedalong each individual lens of the sheet, which focuses the laser beam tomicromachine and bore a corresponding hole into the prefabricated panelthrough the solid, preformed conductive and insulating layers. Theresulting array has a large number of very small bore holes which arethen filled with either a semiconductor material or prefabricated diodesto create a photovoltaic cell, with each concentrating lens designed tobe fifty to 100 times larger than the resulting photovoltaic cell. Dueto the focusing of the lens array, separate solar tracking assembliesare required, to move the entire device to track solar positions,because light is focused on the solar cells from only a small range ofangles, with light incident from other angles being focused on other,non-solar cell portions of the prefabricated panel. This micromachiningmethod did not gain wide acceptance, possibly due to many difficultieswhich were not addressed, such as problems of orienting, aligning andplacing prefabricated diodes into each bore hole; difficulty creating asemiconductor in the bore holes having a crystalline structure ofsufficient quality for efficient functioning; difficulty forming a pnjunction in the region of the bore hole covered by the lens panel (forexposure to the focused light); fabrication problems due to the smallsizes of the bore holes; difficulty with consistent filling of the boreholes; difficulty bonding the applied semiconductor materials orprefabricated diodes to create fully functioning and reliable ohmiccontacts with the remaining (non-ablated), solid conductive layerspreformed in the panel; the creation of short circuits betweenconductive layers from the laser machining debris, etc., for example andwithout limitation. In addition, this method and resulting apparatus isnot useable for creating addressable or dynamic LED displays.

With regard to light emitting devices, various other light emittingapparatus and methods have been oriented toward increasing the amount oflight actually emitted from the light emitting device. For example, LuU.S. Patent Application Publication 2007/0108459, published May 17,2007, entitled “Methods of Manufacturing Light Emitting Devices”,discloses various lens and light extraction structures and geometrieshave been developed in attempting to minimize internal reflection, suchthat light emitted from LEDs is actually output from the device.

Due to such complexities, among other reasons, material andmanufacturing costs for photovoltaic devices and LED-based devices hasremained too high for widespread adoption. As a consequence, a needremains for light emitting and/or photovoltaic apparatuses which aredesigned to be less expensive, in terms of incorporated components andin terms of ease of manufacture. A need also remains for methods tomanufacture such light emitting or photovoltaic devices using lessexpensive and more robust processes, to thereby produce LED-basedlighting devices and photovoltaic panels which therefore may beavailable for widespread use and adoption by consumers and businesses.

SUMMARY OF THE INVENTION

The exemplary embodiments of the present invention provide a new type ofLED-based lighting devices and photovoltaic devices, and new methods ofmanufacturing such devices, using printing and coating technologies. Theinventive photovoltaic and/or LED-based lighting devices may befabricated in a wide variety of sizes, from a size comparable to amobile telephone display, to that of a billboard display (or larger).The exemplary inventive photovoltaic and/or LED-based lighting devicesare also robust and capable of operating under a wide variety ofconditions, including outdoor and other stressful environmentalconditions. The exemplary inventive methods of manufacturingphotovoltaic and/or LED-based lighting devices utilize comparatively lowtemperature processing and create corresponding diodes in situ as thedevice is being manufactured, rather than utilizing finished or packageddiodes (post-manufacturing) which are then subsequently individually andseparately placed into a product in an additional manufacturing cycle.Exemplary inventive lensing structures of the photovoltaic and/orLED-based lighting devices may also provide for mode coupling and awider angle of incidence or dispersion without separate tracking orother panel movement. The exemplary inventive methods of manufacturingphotovoltaic and/or LED-based lighting devices provide for asignificantly reduced cost of a finished product, further enabling thewidespread adoption of such energy-producing and energy-conservingdevices.

In an exemplary embodiment, an apparatus comprises: a base comprising aplurality of spaced-apart channels; a plurality of first conductorscoupled to the base, each first conductor in a corresponding channel ofthe plurality of spaced-apart channels; a plurality of substantiallyspherical diodes coupled to the plurality of first conductors; aplurality of second conductors coupled to the plurality of substantiallyspherical diodes; and a plurality of substantially spherical lenseshaving at least a first index of refraction, the plurality ofsubstantially spherical lenses suspended in a first polymer having atleast a second, different index of refraction.

In various exemplary embodiments, substantially all of the plurality ofsubstantially spherical diodes may have a substantially hemisphericalshell pn junction. Also in various exemplary embodiments, about fifteenpercent to fifty-five percent of a surface of each diode ofsubstantially all of the plurality of substantially spherical diodes mayhave a penetration layer or region having a first majority carrier ordopant and the remaining diode substrate may have a second majoritycarrier or dopant. In additional various exemplary embodiments, eachdiode of the plurality of substantially spherical diodes may comprise afirst part having a substantially hemispherical shell or capped pnjunction and a second part having at least partially spheroid substrate.

In several exemplary embodiments, a ratio of a mean diameter of theplurality of substantially spherical lenses to a mean diameter of theplurality of substantially spherical diodes may be substantially aboutfive to one (5:1). In other various exemplary embodiments, a ratio of amean diameter of the plurality of substantially spherical lenses to amean diameter of the plurality of substantially spherical diodes may bebetween about ten to one (10:1) and two to one (2:1). In variousexemplary embodiments, the comparative size or spacing of the pluralityof substantially spherical lenses may provide a mode coupling to theplurality of substantially spherical diodes. Also in various exemplaryembodiments, a mean diameter of the plurality of substantially sphericaldiodes may be greater than about twenty (20) microns and less than aboutforty (40) microns.

For any of the various exemplary embodiments, the plurality ofsubstantially spherical diodes may be semiconductor light emittingdiodes, organic light emitting diodes, encapsulated organic lightemitting diodes, polymer light emitting diodes, or photovoltaic diodes.For example, the plurality of substantially spherical diodes maycomprise gallium nitride, gallium arsenide, or silicon.

In any of the various exemplary embodiments, a plurality of thirdconductors may be coupled to the plurality of second conductors. Thebase may further comprise a reflector or a refractor, such as a Braggreflector or a reflective plastic or polyester coating. A plurality ofconductive vias may extend between a first side and a second side of thebase and correspondingly coupled at the first side to the plurality offirst conductors. The base also may further comprise a conductivebackplane coupled to the plurality of conductive vias and coupled to orintegrated with the second side of the base. In various exemplaryembodiments, the plurality of conductive vias may comprise a pluralityof substantially randomly distributed, substantially sphericalconductors.

Also in various exemplary embodiments, a plurality of insulators may becorrespondingly coupled to each of the plurality of substantiallyspherical diodes and may comprise a plurality of inorganic dielectricparticles suspended with a photoinitiator compound in a second polymeror resin, or may comprise a photoinitiator compound and a second polymeror resin.

In various exemplary embodiments, the base has a substantially flatoverall form factor with or without surface features and has a thicknessof less than about two millimeters. For example, the base may compriseat least one of the following: paper, coated paper, plastic coatedpaper, embossed paper, fiber paper, cardboard, poster paper, posterboard, wood, plastic, rubber, fabric, glass, and/or ceramic. Theplurality of spaced-apart channels may be substantially parallel, or maybe at least partially hemispherically-shaped and are disposed in anarray, or may be at least partially parabolic. The base may furthercomprise a plurality of angled ridges. The plurality of spaced-apartchannels also may further comprise a plurality of integrally formedprojections or supports. For such an exemplary embodiment, the pluralityof first conductors are coupled to the plurality of integrally formedprojections or supports within the plurality of spaced-apart channelsand the plurality of substantially spherical diodes are alloyed, orannealed, or chemically coupled to the plurality of first conductors.

The plurality of first conductors may comprise a cured conductive ink ora cured conductive polymer. For example, the plurality of firstconductors may comprise at least one of the following types ofconductors in a cured form: a silver conductive ink, a copper conductiveink, a gold conductive ink, an aluminum conductive ink, a tin conductiveink, a carbon conductive ink, a carbon nanotube polymer, or a conductivepolymer. In other various exemplary embodiments, the plurality of firstconductors substantially comprise a sputtered, coated, vapor depositedor electroplated metal, metal alloy, or combination of metals, such as,for example, aluminum, copper, silver, nickel, or gold.

The plurality of second conductors may comprise an opticallytransmissive conductor or conductive compound suspended in a polymer,resin or other media. For example, the plurality of second conductorsmay comprise at least one of the following compounds suspended in apolymer, resin or other media: carbon nanotubes, antimony tin oxide,indium tin oxide, or polyethylene-dioxithiophene.

In several exemplary embodiments, the plurality of lenses may compriseborosilicate glass or polystyrene latex.

In various exemplary embodiments, the plurality of substantiallyspherical diodes are annealed or alloyed to or within the plurality offirst conductors. In other various exemplary embodiments, the pluralityof substantially spherical diodes are chemically coupled to or withinthe plurality of first conductors. In another exemplary embodiment, theplurality of diodes are coupled to or within the plurality of firstconductors by abutment.

An exemplary apparatus or system may further comprise an interface forinsertion into a standardized lighting socket, such as an interfacecompatible with an E12, E14, E26, E27, or GU-10 lighting standard, or aninterface for insertion into a standard Edison-type lighting socket, oran interface for insertion into a standard fluorescent-type lightingsocket.

Another exemplary embodiment is an apparatus, comprising: a base; atleast one first conductor coupled to the base; a plurality ofsubstantially spherical diodes coupled to the at least one firstconductor; at least one second conductor coupled to the plurality ofsubstantially spherical diodes; and a plurality of substantiallyspherical lenses suspended in a first polymer and coupled to theplurality of substantially spherical diodes. In an exemplary embodiment,the plurality of substantially spherical lenses have at least a firstindex of refraction and the first polymer has at least a second,different index of refraction.

Another exemplary apparatus comprises: a base; at least one firstconductor coupled to the base; a plurality of substantially opticallyresonant diodes coupled to the at least one first conductor; at leastone second conductor coupled to the plurality of substantially opticallyresonant diodes; and a plurality of lenses suspended in a first polymerand coupled to the plurality of substantially optically resonant diodes,the plurality of lenses having at least a first index of refraction andthe first polymer having at least a second, different index ofrefraction. In various exemplary embodiments, the plurality ofsubstantially optically resonant diodes may be substantially spherical,substantially toroidal, or substantially cylindrical. Also in variousexemplary embodiments, the plurality of lenses may be substantiallyspherical, hemispherical, faceted, elliptical, oblong, cubic, prismatic,trapezoidal, triangular, or pyramidal.

In various exemplary embodiments, the apparatus may be flexible, orfoldable, or creasable.

An exemplary system is also disclosed, comprising: an interface forinsertion into a standardized lighting socket; a base; at least onefirst conductor coupled to the base; a plurality of substantiallyspherical diodes coupled to the at least one first conductor, theplurality of substantially spherical diodes having a mean diametergreater than about twenty (20) microns and less than about forty (40)microns; at least one insulator coupled to the plurality ofsubstantially spherical diodes; at least one second conductor coupled tothe plurality of substantially spherical diodes; and a plurality ofsubstantially spherical lenses suspended in a polymer and coupled to theplurality of substantially spherical diodes, the plurality ofsubstantially spherical lenses having at least a first index ofrefraction and the polymer having at least a second, different index ofrefraction, wherein a ratio of a mean diameter of the plurality ofsubstantially spherical lenses to the mean diameter of the plurality ofsubstantially spherical diodes is between about ten to one (10:1) andtwo to one (2:1).

Another exemplary apparatus comprises: a base having a plurality ofspaced-apart channels, each channel of the plurality of spaced-apartchannels comprising a plurality of integrally formed projections; aconductive backplane coupled to or integrally formed with the base; aplurality of conductive vias within the base and coupled to theconductive backplane; at least one first conductor coupled to theplurality of conductive vias and to the integrally formed projections; aplurality of substantially spherical diodes coupled to the at least onefirst conductor, about fifteen percent to fifty-five percent of asurface of each diode of substantially all of the plurality ofsubstantially spherical diodes has a penetration layer or region havinga first majority carrier or dopant and the remaining diode substrate hasa second majority carrier or dopant; at least one second conductorcoupled to the plurality of substantially spherical diodes; and aplurality of substantially spherical lenses suspended in a polymer andcoupled to the plurality of substantially spherical diodes.

In several exemplary embodiments, an apparatus comprises: a basecomprising a plurality of spaced-apart channels; a plurality of firstconductors coupled to the base, each first conductor in a correspondingchannel of the plurality of spaced-apart channels; a plurality of diodescoupled to the plurality of first conductors; a plurality of secondconductors coupled to the plurality of diodes; and a plurality ofsubstantially spherical lenses having at least a first index ofrefraction, the plurality of substantially spherical lenses suspended ina first polymer having at least a second, different index of refraction.In various exemplary embodiments, the plurality of diodes may besubstantially spherical, substantially toroidal, substantiallycylindrical, substantially faceted, substantially rectangular,substantially flat, or substantially elliptical.

In another exemplary embodiment, an apparatus comprises: a base; atleast one first conductor coupled to the base; a plurality of diodescoupled to the at least one first conductor; at least one secondconductor coupled to the plurality of diodes; and a plurality ofsubstantially spherical lenses suspended in a first polymer and coupledto the plurality of diodes. In several exemplary embodiments, theplurality of substantially spherical lenses may have at least a firstindex of refraction and the first polymer has at least a second,different index of refraction.

An exemplary system also may comprise: an interface for insertion into astandardized lighting socket; a base; at least one first conductorcoupled to the base; a plurality of diodes coupled to the at least onefirst conductor; at least one second conductor coupled to the pluralityof diodes; and a plurality of lenses suspended in a first polymer andcoupled to the plurality of diodes, the plurality of lenses having atleast a first index of refraction and the first polymer having at leasta second, different index of refraction. In various exemplaryembodiments, the plurality of diodes may be substantially spherical,substantially toroidal, substantially cylindrical, substantiallyfaceted, substantially rectangular, substantially flat, or substantiallyelliptical, and the plurality of lenses may be substantially spherical,hemispherical, faceted, elliptical, oblong, cubic, prismatic,trapezoidal, triangular, or pyramidal.

In an exemplary embodiment, an apparatus comprises: a base; at least onefirst conductor coupled to the base; a plurality of diodes coupled tothe at least one first conductor, about fifteen percent to fifty-fivepercent of a surface of each diode of substantially all of the pluralityof diodes having a layer or region having a first majority carrier ordopant and the remaining diode substrate having a second majoritycarrier or dopant; at least one second conductor coupled to theplurality of diodes; and a plurality of lenses suspended in a firstpolymer and coupled to the plurality of diodes, the plurality of lenseshaving at least a first index of refraction and the first polymer havingat least a second, different index of refraction.

Another exemplary apparatus comprises: a base; at least one firstconductor coupled to the base; a plurality of diodes coupled to the atleast one first conductor; at least one second conductor coupled to theplurality of diodes; and a lens structure coupled to the plurality ofdiodes, the lens structure comprising a plurality of lenses and furtherhaving a plurality of indices of refraction, wherein a ratio of a meandiameter or length of the plurality of lenses to a mean diameter orlength of the plurality of diodes of is between about ten to one (10:1)and two to one (2:1).

Various exemplary embodiments also comprise method of manufacturing anelectronic apparatus, with an exemplary method comprising: forming aplurality of first conductors coupled to a base; coupling a plurality ofsubstantially spherical substrate particles to the plurality of firstconductors; subsequent to the coupling to the plurality of firstconductors, converting the plurality of substantially sphericalsubstrate particles into a plurality of substantially spherical diodes;and forming a plurality of second conductors coupled to the plurality ofsubstantially spherical diodes.

An exemplary method may further comprise depositing a plurality ofsubstantially spherical lenses suspended in a first polymer, and invarious exemplary embodiments, the plurality of substantially sphericallenses may have at least a first index of refraction and wherein thefirst polymer may have at least a second, different index of refraction.The step of depositing may further comprise printing the plurality ofsubstantially spherical lenses suspended in the first polymer over theplurality of substantially spherical diodes and the plurality of secondconductors.

An exemplary method embodiment may further comprise attaching aprefabricated layer to the plurality of substantially spherical diodes,the prefabricated layer comprising a plurality of substantiallyspherical lenses suspended in a first polymer. In various exemplaryembodiments, the step of forming the plurality of first conductors mayfurther comprise depositing a first conductive medium within a pluralityof channels in the base, such as a conductive ink or a conductivepolymer. An exemplary method embodiment may further comprise partiallycuring the first conductive medium, and the step of coupling theplurality of substantially spherical substrate particles to theplurality of first conductors may further comprise depositing within theplurality of channels the plurality of substantially spherical substrateparticles suspended in a carrier medium; and fully curing the firstconductive medium.

In several exemplary embodiments, the step of depositing a firstconductive medium may comprise sputtering, coating, vapor depositing orelectroplating a metal, a metal alloy, or a combination of metals.

In various exemplary embodiments, the step of coupling the plurality ofsubstantially spherical substrate particles to the plurality of firstconductors may further comprise depositing within the plurality ofchannels the plurality of substantially spherical substrate particlessuspended in a reactive carrier medium; removing the reactive carriermedium; and curing or re-curing the first conductive medium. In othervarious exemplary embodiments, the step of coupling the plurality ofsubstantially spherical substrate particles to the plurality of firstconductors may further comprise depositing within the plurality ofchannels the plurality of substantially spherical substrate particlessuspended in an anisotropic conductive medium; and compressing theplurality of substantially spherical substrate particles suspended inthe anisotropic conductive medium. In other various exemplaryembodiments, the step of coupling the plurality of substantiallyspherical substrate particles to the plurality of first conductors mayfurther comprise depositing within the plurality of channels theplurality of substantially spherical substrate particles suspended in avolatile carrier medium; and evaporating the volatile carrier medium. Inyet other various exemplary embodiments, the step of coupling theplurality of substantially spherical substrate particles to theplurality of first conductors may further comprise depositing within theplurality of channels the plurality of substantially spherical substrateparticles suspended in a carrier medium; and annealing or alloying theplurality of substantially spherical substrate particles within theplurality of channels.

In several exemplary embodiments, when the plurality of first conductorsare coupled to a plurality of integrally formed projections or supportswithin the plurality of spaced-apart channels, the step of coupling theplurality of substantially spherical substrate particles to theplurality of first conductors may further comprise depositing within theplurality of channels the plurality of substantially spherical substrateparticles suspended in a carrier medium; and annealing, or alloying, orchemically coupling the plurality of substantially spherical substrateparticles to the plurality of first conductors.

In various exemplary embodiments, when each substantially sphericalsubstrate particle of the plurality of substantially spherical substrateparticles comprises a semiconductor, the step of converting theplurality of substantially spherical substrate particles into theplurality of substantially spherical diodes may further comprise forminga pn junction in each substantially spherical substrate particle bydepositing a dopant material onto the plurality of substantiallyspherical substrate particles and annealing or alloying the dopantmaterial with the plurality of substantially spherical substrateparticles. For example, the annealing or alloying may be laser orthermal annealing or alloying, and the dopant material may be asubstrate liquid or film, or a dopant material may be a dopant elementor compound suspended in a carrier. In several exemplary embodiments,the dopant material may be deposited on a first, upper portion of theplurality of substantially spherical substrate particles to form asubstantially hemispherical shell or capped pn junction.

In several exemplary embodiments, when the plurality of substantiallyspherical substrate particles comprise a first organic or polymercompound, the step of converting the plurality of substantiallyspherical substrate particles into the plurality of substantiallyspherical diodes may further comprise depositing a second organic orpolymer compound onto the plurality of substantially spherical substrateparticles.

An exemplary method embodiment may further comprise depositing aplurality of third conductors over or within the plurality of secondconductors; or coupling a reflector or a refractor to the base, such asa Bragg reflector or a reflective plastic or polyester coating; orattaching an interface for insertion into a standardized lightingsocket.

An exemplary method embodiment may further comprise depositing aplurality of inorganic dielectric particles suspended with aphotoinitiator compound in a second polymer or resin to form a pluralityof insulators correspondingly coupled to each of the plurality ofsubstantially spherical diodes.

In various exemplary embodiments, the step of forming the plurality ofsecond conductors may further comprise depositing an opticallytransmissive conductor or conductive compound suspended in a polymer,resin or other media.

Also in various exemplary embodiments, the forming, coupling andconverting steps are performed by or through a printing process.

Another exemplary method of manufacturing an electronic apparatus isalso disclosed, with the exemplary method comprising: forming at leastone first conductor coupled to a base; coupling a plurality ofsubstantially spherical substrate particles to the at least one firstconductor; converting the plurality of substantially spherical substrateparticles into a plurality of substantially spherical diodes; andforming at least one second conductor coupled to the plurality ofsubstantially spherical diodes. In several exemplary embodiments, anexemplary method may further comprise depositing a plurality ofsubstantially spherical lenses suspended in a first polymer, wherein theplurality of substantially spherical lenses have at least a first indexof refraction and wherein the first polymer has at least a second,different index of refraction. In other various exemplary embodiments,an exemplary method may further comprise attaching a prefabricated layerto the plurality of substantially spherical diodes, with theprefabricated layer comprising a plurality of substantially sphericallenses suspended in a first polymer, wherein the plurality ofsubstantially spherical lenses have at least a first index of refractionand wherein the first polymer has at least a second, different index ofrefraction.

Also in an exemplary embodiment, the step of forming the at least onefirst conductor may further comprise depositing a first conductivemedium, such as a silver conductive ink, a copper conductive ink, a goldconductive ink, an aluminum conductive ink, a tin conductive ink, acarbon conductive ink, a carbon nanotube polymer, or a conductivepolymer. In several exemplary embodiments, the step of depositing afirst conductive medium comprises sputtering, coating, vapor depositingor electroplating a metal, a metal alloy, or a combination of metals,such as aluminum, copper, silver, nickel, or gold.

Another exemplary method of manufacturing a light emitting electronicapparatus is disclosed, with the exemplary method comprising: forming atleast one first conductor coupled to a base; coupling a plurality ofsubstantially spherical substrate particles to the at least one firstconductor; subsequent to the coupling to the at least one firstconductor, converting the plurality of substantially spherical substrateparticles into a plurality of substantially spherical light emittingdiodes, the plurality of substantially spherical light emitting diodeshaving a mean diameter greater than about twenty (20) microns and lessthan about forty (40) microns; forming at least one second conductorcoupled to the plurality of substantially spherical light emittingdiodes; depositing a plurality of substantially spherical lensessuspended in a polymer, the plurality of substantially spherical lenseshaving at least a first index of refraction and the polymer having atleast a second, different index of refraction, wherein a ratio of a meandiameter of the plurality of substantially spherical lenses to a meandiameter of the plurality of substantially spherical light emittingdiodes is between about ten to one (10:1) and two to one (2:1); andattaching an interface for insertion into a standardized lighting socket

Another exemplary method of manufacturing an electronic apparatus isdisclosed and comprises: forming at least one first conductor coupled toa base; coupling a plurality of substantially spherical substrateparticles to the at least one first conductor; subsequent to thecoupling to the at least one first conductor, converting the pluralityof substantially spherical substrate particles into a plurality ofsubstantially spherical diodes, about fifteen percent to fifty-fivepercent of a surface of each diode of substantially all of the pluralityof substantially spherical diodes having a penetration layer or regionhaving a first majority carrier or dopant and the remaining diodesubstrate having a second majority carrier or dopant; forming at leastone second conductor coupled to the plurality of substantially sphericaldiodes; and depositing a plurality of substantially spherical lensessuspended in a polymer, the plurality of substantially spherical lenseshaving at least a first index of refraction and the polymer having atleast a second, different index of refraction.

Another exemplary method of manufacturing an electronic apparatuscomprises: forming a plurality of first conductors coupled to a base;coupling a plurality of substrate particles to the plurality of firstconductors; subsequent to the coupling to the plurality of firstconductors, converting the plurality of substrate particles into aplurality of diodes; forming a plurality of second conductors coupled tothe plurality of diodes; and depositing a plurality of substantiallyspherical lenses suspended in a first polymer, the plurality ofsubstantially spherical lenses having at least a first index ofrefraction and the first polymer having at least a second, differentindex of refraction. In several exemplary embodiments, the plurality ofdiodes may be substantially spherical, substantially toroidal,substantially cylindrical, substantially faceted, substantiallyrectangular, substantially flat, or substantially elliptical. The stepof depositing may further comprise printing the plurality ofsubstantially spherical lenses suspended in the first polymer over theplurality of diodes and the plurality of second conductors.

Yet another exemplary method of manufacturing an electronic apparatuscomprises: forming at least one first conductor coupled to a base;coupling a plurality of substrate particles to the at least one firstconductor; subsequent to the coupling to the at least one firstconductor, converting the plurality of substrate particles into aplurality of diodes; forming at least one second conductor coupled tothe plurality of substantially spherical diodes; and depositing aplurality of substantially spherical lenses suspended in a firstpolymer, wherein the plurality of substantially spherical lenses have atleast a first index of refraction and wherein the first polymer has atleast a second, different index of refraction.

Another exemplary method embodiment for manufacturing an electronicsystem is also disclosed and comprises: forming at least one firstconductor coupled to a base; coupling a plurality of substrate particlesto the at least one first conductor; converting the plurality ofsubstrate particles into a plurality of substantially optically resonantdiodes; forming at least one second conductor coupled to the pluralityof substantially optically resonant diodes; depositing a plurality oflenses suspended in a first polymer, wherein the plurality of lenseshave at least a first index of refraction and wherein the first polymerhas at least a second, different index of refraction; and attaching aninterface for insertion into a standardized lighting socket.

In various exemplary embodiments, a method of manufacturing anelectronic apparatus may comprise: depositing a first conductive mediumwithin a plurality of channels of a base to form a plurality of firstconductors; depositing within the plurality of channels a plurality ofsemiconductor substrate particles suspended in a carrier medium; formingan ohmic contact between each semiconductor substrate particle of theplurality of semiconductor substrate particles and a first conductor ofthe plurality of first conductors; converting the plurality ofsemiconductor substrate particles into a plurality of semiconductordiodes; depositing a second conductive medium to form a plurality ofsecond conductors coupled to the plurality of semiconductor diodes; anddepositing a plurality of lenses suspended in a first polymer over theplurality of diodes. For example, the deposition steps may furthercomprise at least one of the following types of deposition: printing,coating, rolling, spraying, layering, sputtering, lamination, screenprinting, inkjet printing, electro-optical printing, electroinkprinting, photoresist printing, thermal printing, laser jet printing,magnetic printing, pad printing, flexographic printing, hybrid offsetlithography, or Gravure printing. Also for example, the step ofdepositing the first conductive medium may further comprise coating theplurality of channels with the first conductive medium and removingexcess first conductive medium by scraping a first surface of the baseusing a doctor blade, and similarly, the step of depositing theplurality of semiconductor substrate particles may further comprisecoating the plurality of channels with the plurality of semiconductorsubstrate particles suspended in a carrier medium and removing excessplurality of spherical substrate particles by scraping a first surfaceof the base using a doctor blade.

Yet another exemplary method of manufacturing an electronic apparatuscomprises: depositing a first conductive medium on a base to form atleast one first conductor; depositing a plurality of semiconductorsubstrate particles suspended in a carrier medium; forming an ohmiccontact between the plurality of semiconductor substrate particles andthe at least one first conductor; forming a pn junction in eachsemiconductor substrate particle by depositing a dopant onto theplurality of semiconductor substrate particles and annealing theplurality of semiconductor substrate particles to form a plurality ofsemiconductor diodes; depositing a second conductive medium to form atleast one second conductor coupled to the plurality of semiconductordiodes; and depositing a plurality of substantially spherical lensessuspended in a first polymer over the plurality of diodes, the pluralityof substantially spherical lenses having at least a first index ofrefraction and the first polymer having at least a second, differentindex of refraction.

In another exemplary embodiment, a method of manufacturing an electronicapparatus comprises: printing a first conductive medium within aplurality of cavities of a base to form a plurality of first conductors;printing within the plurality of cavities a plurality of substantiallyspherical substrate particles suspended in a carrier medium; printing adopant on first, upper portion the plurality of substantially sphericalsemiconductor substrate particles; annealing the doped plurality ofsubstantially spherical semiconductor substrate particles to form aplurality of substantially spherical diodes having at least a partiallyhemispherical shell pn junction; printing an electrically insulatingmedium over a first portion of the plurality of substantially sphericaldiodes; printing a second conductive medium over a second portion of theplurality of substantially spherical diodes to form a plurality ofsecond conductors; and printing a plurality of substantially sphericallenses suspended in a first polymer over the plurality of substantiallyspherical diodes, the plurality of substantially spherical lenses havingat least a first index of refraction and the first polymer having atleast a second, different index of refraction.

Numerous other advantages and features of the present invention willbecome readily apparent from the following detailed description of theinvention and the embodiments thereof, from the claims and from theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects, features and advantages of the present invention will bemore readily appreciated upon reference to the following disclosure whenconsidered in conjunction with the accompanying drawings, wherein likereference numerals are used to identify identical components in thevarious views, and wherein reference numerals with alphabetic charactersare utilized to identify additional types, instantiations or variationsof a selected component embodiment in the various views, in which:

FIG. 1 is a perspective view of an exemplary base for an apparatusembodiment in accordance with the teachings of the present invention.

FIG. 2 is a cross-sectional view of a first exemplary base for anapparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 3 is a cross-sectional view of a second exemplary base for anapparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 4 is a cross-sectional view of a third exemplary base for anapparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 5 is a cross-sectional view of a fourth exemplary base for anapparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 6 is a perspective view of an exemplary base with a plurality offirst conductors for an apparatus embodiment in accordance with theteachings of the present invention.

FIG. 7 is a cross-sectional view of an exemplary base with a pluralityof first conductors for an apparatus embodiment in accordance with theteachings of the present invention.

FIG. 8 is a cross-sectional view of a fifth exemplary base with aplurality of first conductors for an apparatus embodiment in accordancewith the teachings of the present invention.

FIG. 9 is a cross-sectional view of a sixth exemplary base with aplurality of first conductors for an apparatus embodiment in accordancewith the teachings of the present invention.

FIG. 10 is a cross-sectional view of a sixth exemplary base with aplurality of first conductors for an apparatus embodiment in accordancewith the teachings of the present invention.

FIG. 11 is a perspective view of an exemplary base with a plurality offirst conductors and a plurality of substrate particles for an apparatusembodiment in accordance with the teachings of the present invention.

FIG. 12 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors and a plurality of substrate particles foran apparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 13 is a lateral view of the fifth exemplary base with the pluralityof substrate particles passing through compressive rollers for anoptional step in an exemplary method of forming an apparatus embodimentin accordance with the teachings of the present invention.

FIG. 14 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors and a plurality of diodes for an apparatusembodiment in accordance with the teachings of the present invention.

FIG. 15 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors and a plurality of diodes for an apparatusembodiment in accordance with the teachings of the present invention.

FIG. 16 is a perspective view of an exemplary base with a plurality offirst conductors, a plurality of diodes, and a plurality of insulatorsfor an apparatus embodiment in accordance with the teachings of thepresent invention.

FIG. 17 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors, a plurality of diodes, and a plurality ofinsulators for an apparatus embodiment in accordance with the teachingsof the present invention.

FIG. 18 is a perspective view of an exemplary base with a plurality offirst conductors, a plurality of diodes, a plurality of insulators, anda plurality of second conductors for an apparatus embodiment inaccordance with the teachings of the present invention.

FIG. 19 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors, a plurality of diodes, a plurality ofinsulators, and a plurality of second conductors for an apparatusembodiment in accordance with the teachings of the present invention.

FIG. 20 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors, a plurality of diodes, a plurality ofinsulators, a plurality of second conductors, and an emissive layer foran apparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 21 is a perspective view of an exemplary base with a plurality offirst conductors, a plurality of diodes, a plurality of secondconductors, and a plurality of lenses suspended in a polymer for anapparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 22 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors, a plurality of diodes, a plurality ofinsulators, a plurality of second conductors, a plurality of thirdconductors, and a plurality of lenses suspended in a polymer for anapparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 23 is a perspective view of an exemplary seventh base with aplurality of first conductors, a plurality of diodes, a plurality ofinsulators, a plurality of second conductors, and a plurality of lensessuspended in a polymer for an apparatus embodiment in accordance withthe teachings of the present invention.

FIG. 24 is a cross-sectional view of the seventh exemplary base with aplurality of first conductors, a plurality of diodes, a plurality ofinsulators, a plurality of second conductors, a plurality of thirdconductors, and a plurality of lenses suspended in a polymer for anapparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 25 is a perspective view of an exemplary eighth base for anapparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 26 is a perspective view of an exemplary base with a plurality offirst conductors, a plurality of substantially faceted diodes, aplurality of second conductors, and a plurality of third conductors foran apparatus embodiment in accordance with the teachings of the presentinvention.

FIG. 27 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors, a plurality of substantially faceteddiodes, a plurality of insulators, a plurality of second conductors, anda plurality of third conductors for an apparatus embodiment inaccordance with the teachings of the present invention.

FIG. 28 is a perspective view of an exemplary base with a plurality offirst conductors, a plurality of substantially elliptical (or oblong)diodes, and a plurality of second conductors for an apparatus embodimentin accordance with the teachings of the present invention.

FIG. 29 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors, a plurality of substantially elliptical(or oblong) diodes, a plurality of insulators, and a plurality of secondconductors for an apparatus embodiment in accordance with the teachingsof the present invention.

FIG. 30 is a perspective view of an exemplary base with a plurality offirst conductors, a plurality of substantially irregular diodes, aplurality of insulators, a plurality of second conductors, and aplurality of lenses suspended in a polymer for an apparatus embodimentin accordance with the teachings of the present invention.

FIG. 31 is a cross-sectional view of the fifth exemplary base with aplurality of first conductors, a plurality of substantially irregulardiodes, a plurality of insulators, a plurality of second conductors, anda plurality of lenses suspended in a polymer for an apparatus embodimentin accordance with the teachings of the present invention.

FIG. 32 is a perspective view of a sixth exemplary base with a pluralityof first conductors, a plurality of substantially spherical diodes, aplurality of insulators, a plurality of second conductors, a pluralityof third conductors, and a plurality of lenses suspended in a polymerfor an apparatus embodiment in accordance with the teachings of thepresent invention.

FIG. 33 is a cross-sectional view of the sixth exemplary base with aplurality of first conductors, a plurality of substantially sphericaldiodes, a plurality of insulators, a plurality of second conductors, aplurality of third conductors, and a plurality of lenses suspended in apolymer for an apparatus embodiment in accordance with the teachings ofthe present invention.

FIG. 34 is a perspective view of an exemplary base with a firstconductor, a plurality of substantially spherical diodes, an insulator,a second conductor, and a third conductor for an apparatus embodiment inaccordance with the teachings of the present invention.

FIG. 35 is a perspective view of an exemplary base with a firstconductor, a plurality of substantially spherical diodes, an insulator,a second conductor, a third conductor, and a plurality of lensessuspended in a polymer for an apparatus embodiment in accordance withthe teachings of the present invention.

FIG. 36 is a cross-sectional view of the exemplary base with a firstconductor, a plurality of substantially spherical diodes, an insulator,a second conductor, a third conductor, and a plurality of lensessuspended in a polymer for an apparatus embodiment in accordance withthe teachings of the present invention.

FIG. 37 is a perspective view of a ninth exemplary base with a firstconductor, a first conductor (or conductive) adhesive layer, a pluralityof substrate particles, and an insulator for an apparatus embodiment inaccordance with the teachings of the present invention.

FIG. 38 is a cross-sectional view of the ninth exemplary base with afirst conductor, a first conductor adhesive layer, a plurality ofsubstrate particles, and an insulator for an apparatus embodiment inaccordance with the teachings of the present invention.

FIG. 39 is a perspective view of a ninth exemplary base with a firstconductor, a first conductor (or conductive) adhesive layer, a pluralityof diodes formed using a deposited substrate (or semiconductor) layer orregion over a plurality of substrate particles, an insulator, a secondconductor, and a plurality of lenses (suspended in a polymer (resin orother binder)) having been deposited for an exemplary apparatusembodiment in accordance with the teachings of the present invention.

FIG. 40 is a cross-sectional view of the ninth exemplary base with afirst conductor, a first conductor (or conductive) adhesive layer, aplurality of diodes formed using a deposited substrate (orsemiconductor) layer or region over a plurality of substrate particles,an insulator, a second conductor, and a plurality of lenses (suspendedin a polymer (resin or other binder)) having been deposited for anexemplary apparatus embodiment in accordance with the teachings of thepresent invention.

FIG. 41 is a block diagram illustrating a first system embodiment inaccordance with the teachings of the present invention.

FIG. 42 is a block diagram illustrating a second system embodiment inaccordance with the teachings of the present invention.

FIG. 43 is a flow chart illustrating a method embodiment in accordancewith the teachings of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

While the present invention is susceptible of embodiment in manydifferent forms, there are shown in the drawings and will be describedherein in detail specific exemplary embodiments thereof, with theunderstanding that the present disclosure is to be considered as anexemplification of the principles of the invention and is not intendedto limit the invention to the specific embodiments illustrated. In thisrespect, before explaining at least one embodiment consistent with thepresent invention in detail, it is to be understood that the inventionis not limited in its application to the details of construction and tothe arrangements of components set forth above and below, illustrated inthe drawings, or as described in the examples. Methods and apparatusesconsistent with the present invention are capable of other embodimentsand of being practiced and carried out in various ways. Also, it is tobe understood that the phraseology and terminology employed herein, aswell as the abstract included below, are for the purposes of descriptionand should not be regarded as limiting.

For selected embodiments, the invention disclosed herein is related toU.S. patent application Ser. No. 11/756,616, filed May 31, 2007,inventors William Johnstone Ray et al., entitled “Method ofManufacturing Addressable and Static Electronic Displays” and to U.S.patent application Ser. No. 11/756,619, filed May 31, 2007, inventorsWilliam Johnstone Ray et al., entitled “Addressable or Static LightEmitting or Electronic Apparatus” (the “related applications”), whichare commonly assigned herewith, the contents of all of which areincorporated herein by reference in their entireties, and with priorityclaimed for all commonly disclosed subject matter.

FIG. 1 is a perspective view of an exemplary base 100, 100A, 100B, 100C,100D for an apparatus embodiment in accordance with the teachings of thepresent invention. FIG. 2 is a cross-sectional view (through the 25-25′plane) of a first exemplary base 100 for an apparatus embodiment inaccordance with the teachings of the present invention. FIG. 3 is across-sectional view (through the 25-25′ plane) of a second exemplarybase 100A for an apparatus embodiment in accordance with the teachingsof the present invention. FIG. 4 is a cross-sectional view (through the25-25′ plane) of a third exemplary base 100B for an apparatus embodimentin accordance with the teachings of the present invention. FIG. 5 is across-sectional view (through the 25-25′ plane) of a fourth exemplarybase 100C for an apparatus embodiment in accordance with the teachingsof the present invention. It should be noted that in many of the variousperspective or lateral views (such as FIGS. 1, 6, 11, 13, 16, 18, 21,26, 28, 34, 35), any one or more corresponding bases 100 may beutilized, with various cross sections (such as FIGS. 2-5, 7, 8, 12, 14,15, 17, 19, 20, 22, 27, 29) considered particular exemplary instances orinstantiations when that corresponding base is utilized as shown in acorresponding perspective view. It also should be noted that anyreference to apparatus, such as an apparatus 200, 300, 400, 500, 600and/or 700, should be understood to mean and include its or theirvariants, and vice-versa, including apparatuses 200A, 200B, 300A, 300B,400A, 400B, 500A, 500B, 600A, 600B, 700A, and 700B discussed below. Inaddition, it should be noted that apparatuses 200, 200A, 200B, 300,300A, 300B, 400, 400A, 400B, 500, 500A, 500B, 600, 600A, 600B, 700A, and700B may differ from one another concerning any one or more of thefollowing, as discussed in greater detail below: (1) the existence ofand/or shape of any cavities, channels or grooves 105 within theircorresponding bases 100; (2) the shape of the substrate (orsemiconductor) particles 120 and/or lenses 150; (3) having single layersof conductors and insulators, rather than pluralities; (4) inclusion ofintegrally formed or other conductive vias 280, 285; (5) inclusion of abackplane 290; (6) deposition methods utilized to create thecorresponding apparatuses; etc. Further, apparatuses 200A, 300A, 400A,500A, 600A, 700A, differ from apparatuses 200B, 300B, 400B, 500B, 600B,700B insofar as incorporated diodes 155 are light emitting diodes forapparatuses 200A, 300A, 400A, 500A, 600A, 700A and photovoltaic diodesfor apparatuses 200B, 300B, 400B, 500B, 600B, 700B, also as discussed ingreater detail below. Otherwise, any reference to any feature or elementof any of an apparatus 200, 300, 400, 500, 600 and/or 700 should beunderstood to be equally applicable to any of the other apparatus 200,300, 400, 500, 600 and/or 700 embodiments, individually and/or withcombinations of such features or elements, such that any apparatus 200,300, 400, 500, 600 and/or 700 may include or comprise any of theelements of any of the other apparatus 200, 300, 400, 500, 600 and/or700 embodiments, in any combination. In addition, any and all of thevarious deposition, process and/or other manufacturing steps areapplicable to any of the various apparatuses 200, 300, 400, 500, 600and/or 700.

It should also be noted that the term “substrate” may utilized to referto two different components, a base (supporting or foundationalsubstrate) 100 (including 100A-100H) which forms a base or support forother components, and which may be referred to herein equivalently as a“substrate” in the related applications, such as for printing variouslayers on a substrate, and a plurality of substrate particles 120, suchas a plurality of semiconductor, polymer, or organic light emitting orphotovoltaic substrate particles utilized to form corresponding diodes155. Those having skill in the art will recognize that these varioussubstrates are different based upon both the context and thecorresponding reference numerals, and to avoid confusion, a supporting-or foundational-type substrate will be referred to herein as a “base”,with “substrate” utilized in the typical sense of the electronics and/orsemiconductor art to mean and refer to the material comprising substrateparticles 120.

As illustrated in FIGS. 1 through 5, an exemplary base 100, 100A, 100B,100C, 100D (and 100E-100G discussed below) includes a plurality ofcavities (channels, trenches or voids) 105, which for the selectedembodiment, are formed as elongated cavities, effectively formingchannels, grooves or slots (or, equivalently, depressions, valleys,bores, openings, gaps, orifices, hollows, slits, passages, orcorrugations), which are separated from each other by a correspondingplurality of ridges (peaks, raised portions or crests) 115 of theexemplary base 100, 100A-100G. While the cavity, channel or groove 105for bases 100, 100A, 100B, 100C, 100D is illustrated as curved(semi-circular or semi-elliptical) and extending substantially straight(in the direction perpendicular to the 25-25′ plane), any and allcavities, channels or grooves 105 of any shape and/or size and extendingin any one or more directions are considered equivalent and within thescope of the invention as claimed, including without limitation square,rectangular, curvilinear, wavy, irregular, differently sized, etc., withadditional exemplary shapes of cavities, channels or grooves 105illustrated in other Figures and discussed below. The plurality ofcavities, channels or grooves 105 are spaced-apart, and as illustratedseparated from each other by the ridges (peaks, raised portions orcrests) 115, and will be utilized to shape and define a plurality offirst conductors 110 for selected embodiments, as discussed below. Whilethe cavities or channels 105 are illustrated in FIG. 1 and other Figuresas substantially parallel and oriented in substantially the samedirection, those having skill in the art will recognize that innumerablevariations are available, including depth and width of the channels,channel direction or orientation (e.g., circular, elliptical,curvilinear, wavy, sinusoidal, triangular, fanciful, artistic,irregular, etc.), spacing variations, type of void or cavity (e.g.,channel, depression or bore), etc., and all such variations areconsidered equivalent and within the scope of the present invention.Bases 100 having additional forms are also illustrated and discussedbelow with reference to FIGS. 9, 10, 23-25, 30-33, and 37-39. Forexample, an exemplary base 100H which has a substantially flat overallform factor and is without any significant surface variation (i.e., doesnot have any cavities, channels or grooves 105) is illustrated anddiscussed below with reference to FIGS. 37-39.

A base 100, 100A, 100B, 100C, 100D (and the other bases 100E, 100F,100G, 100H discussed below) may be formed from or comprise any suitablematerial, such as plastic, paper, cardboard, or coated paper orcardboard, for example and without limitation. In an exemplaryembodiment, a base 100 (including 100A, 100B, 100C, 100D, 100E, 100Fand/or 100G) comprises an embossed and coated paper or plastic havingthe plurality of cavities 105 formed integrally therein, such as througha molding process, including an embossed paper or embossed paper boardcommercially available from Sappi, Ltd., for example. Also in anexemplary embodiment, base 100 (including 100A, 100B, 100C, 100D, 100E,100F, 100G and/or 100H) comprises a material having a dielectricconstant capable of or suitable for providing substantial electricalinsulation. A base 100, 100A, 100B, 100C, 100D, 100E, 100F, 100G, 100Hmay comprise, also for example, any one or more of the following: paper,coated paper, plastic coated paper, fiber paper, cardboard, posterpaper, poster board, books, magazines, newspapers, wooden boards,plywood, and other paper or wood-based products in any selected form;plastic or polymer materials in any selected form (sheets, film, boards,and so on); natural and synthetic rubber materials and products in anyselected form; natural and synthetic fabrics in any selected form;glass, ceramic, and other silicon or silica-derived materials andproducts, in any selected form; concrete (cured), stone, and otherbuilding materials and products; or any other product, currentlyexisting or created in the future. In a first exemplary embodiment, abase 100, 100A, 100B, 100C, 100D, 100E, 100F, 100G, 100H may be selectedwhich provides a degree of electrical insulation (i.e., has a dielectricconstant or insulating properties sufficient to provide electricalinsulation of the one or more first conductors 110 deposited or appliedon a first (front) side of the base 100 (including 100A, 100B, 100C,100D, 100E, 100F, 100G and/or 100H), either electrical insulation fromeach other or from other apparatus or system components. For example,while comparatively expensive choices, a glass sheet or a silicon waferalso could be utilized as a base 100, 100A, 100B, 100C, 100D, 100E,100F, 100G, 100H. In other exemplary embodiments, however, a plasticsheet or a plastic-coated paper product is utilized to form the base100, 100A, 100B, 100C, 100D, 100E, 100F, 100G, 100H such as the patentstock and 100 lb. cover stock available from Sappi, Ltd., or similarcoated papers from other paper manufacturers such as Mitsubishi PaperMills, Mead, and other paper products. In additional exemplaryembodiments, any type of base 100, 100A, 100B, 100C, 100D, 100E, 100F,100G, 100H may be utilized, including without limitation, those withadditional sealing or encapsulating layers (such as plastic, lacquer andvinyl) deposited to one or more surfaces of the base 100, 100A, 100B,100C, 100D, 100E, 100F, 100G, 100H.

The exemplary bases 100 as illustrated in the various Figures have aform factor which is substantially flat in an overall sense, such ascomprising a sheet of a selected material (e.g., paper or plastic) whichmay be fed through a printing press, for example and without limitation,and which may have a topology on a first surface (or side) whichincludes cavities, channels or grooves 105 (e.g., reticulated,substantially flat bases 100, 100A, 100B, 100C, 100D, 100E, 100F, 100G)or having a first surface which is substantially smooth (substantiallysmooth and substantially flat base 100H) within a predeterminedtolerance (and does not include cavities, channels or grooves 105).Those having skill in the art will recognize that innumerable,additional shapes and surface topologies are available, are consideredequivalent and within the scope of the claimed invention.

Referring to FIG. 3, a second exemplary base 100A further comprises twoadditional components or features, any of which may be integrally formedas part of second exemplary base 100A, or which may be deposited overanother material, such as a base 100, to form a second exemplary base100A. As illustrated, the second exemplary base 100A further comprises areflector, refractor or mirror 250, such as an optical grating, a Braggreflector or mirror, which may be covered by a coating 260, such as asubstantially clear plastic coating (e.g., polyester, mylar, etc.), orhaving any suitable index of refraction, such that the interior of thecavities, channels or grooves 105 is substantially smooth (particularlywhen the reflector, refractor or mirror 250 may be implemented as arefractive grating, for example). The reflector, refractor or mirror 250is utilized to reflect incident light either back toward the cavities,channels or grooves 105 (and any incorporated diodes 155, discussedbelow, such as for photovoltaic applications) or toward the (first)surface of an apparatus (200, 300, 400, 500, 600 and/or 700) having thecavities, channels or grooves 105.

Referring to FIG. 4, a third exemplary base 100B further comprises areflective coating 270, such as an aluminum or silver coated polyesteror plastic, for example, which may be integrally formed as part of thirdexemplary base 100B, or which may be deposited over another material,such as a base 100, to form a third exemplary base 100B. The reflectivecoating 270 is also utilized to reflect incident light either backtoward the cavities, channels or grooves 105 (and any incorporateddiodes 155, discussed below, such as for photovoltaic applications) ortoward the surface of the apparatus (200, 300, 400, 500, 600 and/or 700)having the cavities, channels or grooves 105. The reflector, refractoror mirror 250 or the reflective coating 270 is generally selected toreflect or refract light at a wavelength appropriate for a selectedbandgap of the plurality of diodes 155 discussed below, depending uponthe selected application.

Referring to FIG. 5, a fourth exemplary base 100C may include any of thecoatings and/or reflectors discussed above (250, 260, 270), and alsofurther comprises any of two additional components or features, aplurality of conductive vias 280 and a conductive backplane 290, any ofwhich may be integrally formed as part of fourth exemplary base 100C, orwhich may be deposited or applied over or within another material, suchas a base 100, to form a fourth exemplary base 100C. For example,exemplary conductive vias 280 may be formed by filling a correspondingvoid in the fourth exemplary base 100C with a conductive ink or polymer,such as during deposition of the first plurality of conductors 110discussed below. Also for example, the conductive vias 280 may beintegrally formed with the fourth exemplary base 100C, such as formed ofmetal, carbon or other conductive pins or wires which are embeddedwithin a plastic sheet to form the fourth exemplary base 100C. Anothervariation of conductive vias (as distributed (randomly or regularly),substantially spherical conductive vias 285) is illustrated anddiscussed below with reference to FIGS. 10 and 33. Also for example,there may be one or more conductive vias 280, 285 for each correspondingfirst conductor 110. As another example, a conductive backplane 290 maybe formed integrally with the base 100C or deposited over a base (100),such as by coating or printing the second (back) side or surface of thebase 100 with a conductive ink or polymer, such as the exemplaryconductive inks or polymers described below. As illustrated, either orboth a plurality of conductive vias 280 (and/or conductive vias 285)and/or a conductive backplane 290 may be formed from any conductivesubstance of any kind or type, such as a metal, a conductive ink orpolymer, or various other conductive materials, such as carbon or carbonnanotubes, including any of the materials which may comprise the first,second and/or third conductors (110, 140, 145, respectively) describedbelow, for example and without limitation. The conductive vias 280(and/or conductive vias 285) are utilized to couple, connect, andotherwise conduct to and/or from the one or more first conductors 110(discussed below). The conductive backplane 290 provides a convenientelectrical coupling or connection between the conductive vias 280, 285and other system (350, 375) components, and may also function as anelectrode, for example, to apply a voltage or current to the apparatus200, 300, 400, 500, 600, 700 or to receive a voltage or currentgenerated by the apparatus 200, 300, 400, 500, 600, 700. In otherexemplary embodiments, separate wires, leads or other connections may beprovided to each, some or all of the vias 280, in lieu of or in additionto a conductive backplane 290, such as for different types ofaddressability, as discussed in greater below. (In other exemplaryembodiments implemented without vias 280 (285) and/or a conductivebackplane 290, other types of contacts may be made to the plurality offirst conductors 110, such as from the sides or edges of the apparatus200, 300, 400, 500, 600, 700, as discussed below.) Conductive vias 280and/or a conductive backplane 290 may also be included within any of theother bases 100, 100A, 100B, 100D, 100E, 100F, 100G, 100H, and all suchvariations are considered equivalent and within the scope of the claimedinvention.

A fifth exemplary base 100D is discussed below with reference to FIG. 8,and combines the various features of the second exemplary base 100A andthe fourth exemplary base 100C. Additional sixth, seventh and eighthbases 100G, 100E and 100F are also discussed below, having differentforms for cavities, channels or grooves 105, such as semicircularchannels 105 with interior projections (or supports) 245, off-axisparabolic (paraboloid) shaped channels 105A, and substantiallyhemispherical cavities 105B, with a ninth exemplary base 100H with afirst side or surface having a substantially smooth surface topologywithout cavities, channels or grooves 105.

The various cavities, channels or grooves 105 may have any type or kindof spacing between or among them. For example, in an exemplaryembodiment, pairs of cavities, channels or grooves 105 are spacedcomparatively closer together, with a comparatively larger spacingbetween each such pair of cavities, channels or grooves 105, providingcorresponding spacing for one or more first conductors 110 depositedwithin the cavities, channels or grooves 105, as discussed in greaterdetail below.

In accordance with the claimed invention, one or more first conductors110 are then applied or deposited (on a first side or surface of thebase 100) within the corresponding plurality of cavities, channels orgrooves 105, or over all or part of the first surface or side or thebase 100, such as through a printing process. FIG. 6 is a perspectiveview of an exemplary base 100, 100A, 100B, 100C, 100D with a pluralityof first conductors 110 for an apparatus embodiment in accordance withthe teachings of the present invention. FIG. 7 is a cross-sectional view(through the 30-30′ plane) of an exemplary base 100 with a plurality offirst conductors 110 for an apparatus embodiment in accordance with theteachings of the present invention. FIG. 8 is a cross-sectional view(through the 30-30′ plane) of a exemplary base 100D with a plurality offirst conductors 110 for an apparatus embodiment in accordance with theteachings of the present invention. As mentioned above, exemplary base100D further comprises cavities, channels or grooves 105 (which areillustrated in FIG. 8 as partially filled with one or more firstconductors 110), a reflector, refractor or mirror 250, a coating 260,one or more conductive vias 280 (or 285), and a conductive backplane290.

In an exemplary method of manufacturing the exemplary apparatuses 200,300, 400, 500, 600 and/or 700, a conductive ink, polymer, or otherconductive liquid or gel (such as a silver (Ag) ink or polymer or acarbon nanotube ink or polymer) is deposited on a base 100, 100A, 100B,100C, 100D, 100E, 100F, 100G, 100H, such as through a printing or otherdeposition process, and may be subsequently cured or partially cured(such as through an ultraviolet (uv) curing process), to form the one ormore first conductors 110 (and such conductive inks or polymers also maybe utilized to form any of the other conductors, such as the conductivevias 280, 285 or the conductive backplane 290). In another exemplaryembodiment, the one or more first conductors 110, the conductive vias280, 285, and/or the conductive backplane 290 may be formed bysputtering, spin casting (or spin coating), vapor deposition, orelectroplating of a conductive compound or element, such as a metal(e.g., aluminum, copper, silver, gold, nickel). Combinations ofdifferent types of conductors and/or conductive compounds or materials(e.g., ink, polymer, elemental metal, etc.) may also be utilized togenerate one or more composite first conductors 110. Multiple layersand/or types of metal or other conductive materials may be combined toform the one or more first conductors 110, the conductive vias 280, 285,and/or the conductive backplane 290, such as first conductors 110comprising gold plate over nickel, for example and without limitation.In various exemplary embodiments, a plurality of first conductors 110are deposited in corresponding cavities, channels or grooves 105, and inother embodiments, a first conductor 110 may be deposited as a singleconductive sheet (FIGS. 34-40) or otherwise attached (e.g., a sheet ofaluminum coupled to a base 100H). Also in various embodiments,conductive inks or polymers which may be utilized to form the pluralityof first conductors 110 may not be cured or may be only partially curedprior to deposition of a plurality of substrate (or semiconductor)particles 120, and then fully cured while in contact with the pluralityof substrate (or semiconductor) particles 120, such as for creation ofohmic contacts with the plurality of substrate (or semiconductor)particles 120 as discussed below.

Other conductive inks or materials may also be utilized to form thefirst conductors 110, conductive vias 280, 285, conductive backplane290, second conductors 140, third conductors 145, and any otherconductors discussed below, such as copper, tin, aluminum, gold, noblemetals, carbon, carbon nanotube (“CNT”), or other organic or inorganicconductive polymers, inks, gels or other liquid or semi-solid materials.In addition, any other printable or coatable conductive substances maybe utilized equivalently to form the first conductors 110, conductivevias 280, 285, conductive backplane 290, second conductors 140 and/orthird conductors 145, and exemplary conductive compounds include: (1)from Conductive Compounds (Londonberry, N.H., USA), AG-500, AG-800 andAG-510 Silver conductive inks, which may also include an additionalcoating UV-1006S ultraviolet curable dielectric (such as part of a firstdielectric layer 125); (2) from DuPont, 7102 Carbon Conductor (ifoverprinting 5000 Ag), 7105 Carbon Conductor, 5000 Silver Conductor(also for bus 310, 315 of FIG. 42 and any terminations), 7144 CarbonConductor (with UV Encapsulants), 7152 Carbon Conductor (with 7165Encapsulant), and 9145 Silver Conductor (also for bus 310, 315 of FIG.42 and any terminations); (3) from SunPoly, Inc., 128A Silver conductiveink, 129A Silver and Carbon Conductive Ink, 140A Conductive Ink, and150A Silver Conductive Ink; (4) from Dow Corning, Inc., PI-2000 SeriesHighly Conductive Silver Ink; and (5) from Henckel/Emerson & Cumings,725A. As discussed below, these compounds may also be utilized to formother conductors, including the plurality of second conductors 140 andany other conductive traces or connections. In addition, conductive inksand compounds may be available from a wide variety of other sources.

Conductive polymers which are substantially optically transmissive mayalso be utilized to form the one or more first conductors 110,conductive vias 280, 285, conductive backplane 290, and also theplurality of second conductors 140 and/or third conductors 145. Forexample, polyethylene-dioxithiophene may be utilized, such as thepolyethylene-dioxithiophene commercially available under the trade name“Orgacon” from AGFA Corp. of Ridgefield Park, N.J., USA, in addition toany of the other transmissive conductors discussed below and theirequivalents. Other conductive polymers, without limitation, which may beutilized equivalently include polyaniline and polypyrrole polymers, forexample. In another exemplary embodiment, carbon nanotubes which havebeen suspended or dispersed in a polymerizable ionic liquid are utilizedto form various conductors which are substantially opticallytransmissive or transparent, such as one or more second conductors 140.

Various textures may be provided for the one or more first conductors110, such as having a comparatively rough or spiky surface, tofacilitate subsequent forming of ohmic contacts with a plurality ofsubstrate particles 120 discussed below. One or more first conductors110 may also be given a corona treatment prior to deposition of theplurality of substrate particles 120, which may tend to remove anyoxides which may have formed, and also facilitate subsequent forming ofohmic contacts with the plurality of substrate particles 120.

In an exemplary embodiment, an embossed base 100, 100A, 100B, 100C,100D, 100E, 100F, 100G is utilized, such that the base 100, 100A, 100B,100C, 100D, 100E, 100F, 100G has an alternating series of ridges forming(generally smooth) peaks (crests) and valleys (cavities, channels orgrooves 105), generally having a substantially parallel orientation (asan example), respectively illustrated as raised (or non-channel)portions or crests 115 and cavities (e.g., channels) 105. Conductiveinks, polymers or other conductors may then be deposited to remain inthe embossed valleys, creating a plurality of first conductors 110 whichare not only substantially parallel, but which also have a physicalseparation from each other determined by the ridges (peaks, raisedportions or crests) 115 provided through an embossing process, forexample. Indeed, when the conductive inks or polymers are deposited tothe embossed valleys (cavities, channels or grooves 105), thecorresponding first plurality of conductors 110 are also separated fromeach other by the embossed ridges (peaks, raised portions or crests) 115of the base 100, creating both a physical separation and electricalinsulation (insulated through a corresponding dielectric constant), inaddition to being spaced apart. For example, conductive inks or polymersmay be coated or otherwise deposited to an embossed base in itsentirety, and then utilizing a “doctor blade”, the conductive inks orpolymers are removed from all of the peaks (crests or raised portions115), such as by scraping the blade across the surface of the base 100,100A, 100B, 100C, 100D, 100E, 100F, 100G having a coating of aconductive ink, leaving the conductive inks or polymers within thecavities, channels or grooves 105 to form a first plurality ofconductors 110 having a substantially parallel orientation. The amountof conductive ink or polymer remaining in the cavities, channels orgrooves 105 depends on the type of doctor blade and the appliedpressure. Alternatively, conductive inks or polymers also may bedeposited (using negligible or zero pressure) on the embossed peaks(crests or raised portions 115), such as by tip printing, leaving theconductive inks or polymers to form a plurality of conductors having asubstantially parallel orientation, such as for forming the plurality ofsecond conductors 140 or a plurality of third conductors 145. Suchprinting may be performed as a separate manufacturing step discussedbelow.

For example, a conductive ink may be coated or otherwise deposited inexcess over the entire or most of the first side or surface of the base100, 100A, 100B, 100C, 100D, 100E, 100F, 100G, with the excessconductive ink subsequently removed using a “doctor blade” or other typeof scraping as known in the printing arts, followed by uv curing of theconductive ink within the plurality of cavities, channels or grooves105. Using such a doctor blade, the conductive ink within the pluralityof cavities, channels or grooves 105 is allowed to remain in place, withthe balance of the conductive ink (such as covering the non-channelportions of the base (crests or raised portions 115) being removed bythe scraping process, such as due to contact from the doctor blade.Depending upon the type of printing, including the stiffness of thedoctor blade and the applied pressure, the conductive ink may form ameniscus within each of the plurality of cavities, channels or grooves105 or may bow upward instead, for example. Those having skill in theelectronic or printing arts will recognize innumerable variations in theways in which the plurality of first conductors 110 may be formed, withall such variations considered equivalent and within the scope of thepresent invention. For example, the one or more first conductors 110 mayalso be deposited through sputtering or vapor deposition, withoutlimitation. In addition, for other various embodiments, the firstconductor(s) 110 may be deposited as a single or continuous layer, suchas through coating, printing, sputtering, or vapor deposition, such asfor the exemplary embodiments illustrated and discussed below withreference to FIGS. 34-40.

As a consequence, as used herein, “deposition” means, refers to andincludes any and all printing, coating, rolling, spraying, layering,sputtering, plating, spin casting (or spin coating), vapor deposition,lamination, affixing and/or other deposition processes, whether impactor non-impact, currently known or developed in the future, and“printing” means, refers to and includes any and all printing, coating,rolling, spraying, layering, spin coating, lamination and/or affixingprocesses, whether impact or non-impact, currently known or developed inthe future, including without limitation screen printing, inkjetprinting, electro-optical printing, electroink printing, photoresist andother resist printing, thermal printing, laser jet printing, magneticprinting, pad printing, flexographic printing, hybrid offsetlithography, Gravure and other intaglio printing, for example. All suchprocesses are considered deposition processes herein, may be utilizedequivalently, and are within the scope of the present invention. Alsosignificant, the exemplary deposition or printing processes do notrequire significant manufacturing controls or restrictions. No specifictemperatures or pressures are required. No clean room or filtered air isrequired beyond the standards of known printing or other depositionprocesses. For consistency, however, such as for proper alignment(registration) of the various successively deposited layers forming thevarious embodiments, relatively constant temperature (with a possibleexception, discussed below) and humidity may be desirable. In addition,the various compounds utilized may be contained within various polymers,binders or other dispersion agents which may be heat-cured or dried, airdried under ambient conditions, or uv cured, for example, and all suchvariations are within the scope of the present invention.

A particular advantage of use of a base 100, 100A, 100B, 100C, 100D,100E, 100F, 100G having a plurality of cavities 105 is that printingregistration is not required to be exact, and a one-dimensional orrelative registration may be sufficient for the successive applicationsof the different materials and layers forming the apparatus 200, 300,400, 500, 600 and/or 700.

Depending upon the selected embodiment, the depth of the plurality ofcavities, channels or grooves 105 may vary from comparatively deep(e.g., one-half or more of the diameter of a substrate (semiconductor)particle 120) to comparatively shallow (e.g., less than one-half of thediameter of a substrate (semiconductor) particle 120). In addition, aspreviously mentioned, a base (100H) may have a surface topology which issubstantially flat, smooth or even, without a plurality of cavities,channels or grooves 105 integrally formed therein, such as forapplication of the one or more first conductors 110 as a unitaryconductive sheet or layer, without being spaced apart or electricallyinsulated from each other. In other exemplary embodiments, a base mayhave a substantially flat, smooth or even surface, without a pluralityof cavities, channels or grooves 105 integrally formed therein, andinstead having ridges (crests or raised portions 115) or other forms ofseparation built or deposited onto the base which in turn form cavities,channels or grooves 105, or no ridges (crests or raised portions 115).

It should also be noted, generally for any of the applications ofvarious compounds herein, such as through printing or other deposition,the surface properties or surface energies may also be controlled, suchas through the use of resist coatings or by otherwise modifying the“wetability” of such a surface, for example, by modifying thehydrophilic, hydrophobic, or electrical (positive or negative charge)characteristics, for example, of surfaces such as the surface of thebase 100 (including 100A, 100B, 100C, 100D, 100E, 100F, 100G and/or100H), the surfaces of the various first, second and/or third conductors(110, 140, 145, respectively), and/or the surfaces of the plurality ofsubstrate particles 120 discussed below. In conjunction with thecharacteristics of the compound, suspension, polymer or ink beingdeposited, such as the surface tension, the deposited compounds may bemade to adhere to desired or selected locations, and effectivelyrepelled from other areas or regions.

FIG. 9 is a cross-sectional view of a sixth exemplary base 100G with aplurality of first conductors 110 for an apparatus embodiment inaccordance with the teachings of the present invention. FIG. 10 is across-sectional view (through the 31-31′ plane) of the sixth exemplarybase 100G with a plurality of first conductors 110 for an apparatusembodiment in accordance with the teachings of the present invention.The sixth exemplary base 100G differs from the other exemplary bases100-100F insofar as the sixth exemplary base 100G also comprises aplurality of integrally formed projections or supports (equivalently,extensions, protrusions, protuberances, etc.) 245 and a plurality ofintegrally formed conductive vias 285 (as a variation of the vias 280).As illustrated, each of the projections (or supports) 245 are continuousand extend as a solid, raised rail down the entire length of the channel105; in other embodiments not separately illustrated, the projections(or supports) 245 may be discrete and discontinuous, such as projections(or supports) 245 having the shape of individual horns or spikes whichare spaced apart and located at intervals (regular or irregular) downthe length of a channel 105, for example and without limitation. Theprojections (or supports) 245 may have any suitable form, includingbeing smooth and continuous or sharp and discontinuous, with all suchvariations considered equivalent and within the scope of the claimedinvention. In an exemplary embodiment, the projections (or supports) 245are shaped to allow them to be integrally formed as part of the base100G, such as by a casting or other molding method, also for example andwithout limitation.

Also as illustrated, the plurality of first conductors 110 have beendeposited to be conformal and track the shape of the channels 105 with asubstantially uniform thickness (i.e., a substantially even coatingsubstantially following the contour of the first side (surface) of thebase 100G). In an exemplary embodiment, a conductor (such as a metal)may be deposited (at a comparatively low temperature), such as bysputtering, spin casting (or spin coating), coating, or vapordeposition, over the entire first surface (side) of the base 100G,followed by substantially removing any conductor on the ridges (peaks,raised portions or crests) 115, such as by grinding or sanding theridges (peaks, raised portions or crests) 115 of the base 100G, leavingthe plurality of first conductors 110 remaining within the channels 105.In another exemplary embodiment, a resist coating is deposited to theridges (peaks, raised portions or crests) 115, and a conductor (such asa metal) may be deposited, such as by sputtering, spin casting (or spincoating), or vapor deposition, over the entire first surface of the base100G, followed by substantially removing any conductor on the ridges(peaks, raised portions or crests) 115, such as by dissolving the resistor by lifting off the conductor on the resist over the ridges (peaks,raised portions or crests) 115, and dissolving any remaining resist. Inthis latter method, the conductor may be deposited directionally, sothat the deposited conductor is discontinuous at the edges of the ridges(peaks, raised portions or crests) 115, enabling the conductor on theridges (peaks, raised portions or crests) 115 to be removed withoutaffecting the remaining conductor deposited within the channels 105.When the selected conductor is aluminum, the first conductors 110 arealso significantly reflective and capable of functioning as a reflectiveor mirror coating, in addition to providing conductance.

As discussed in greater detail below with reference to FIGS. 11, 12 and33, the projections (or supports) 245 serve to elevate (or support) aplurality of substrate particles 120 above the bottom or remainingportion of the channel 105. As the plurality of substrate particles 120are suspended in a carrier (liquid or gel, for example) for depositionwithin the channels 105, the elevation by the projections 245 providesfor physically supporting and/or separating the plurality of substrateparticles 120 from the suspending carrier (which at least initiallyremains at the bottom of the channel 105 and/or which may be dissipatedor removed (such as through evaporation)). The first conductors 110 (onthe projections 245) then form ohmic contacts with the supported andelevated substrate particles 120, without interference (or withdiminished interference) from any suspending carrier (or polymers orresins) which may be remaining.

The plurality of integrally formed conductive vias 285, as illustrated,may comprise any type of conductor or conductive medium, as previouslydiscussed and without limitation, and may have any suitable shape orform. In an exemplary embodiment, the conductive vias 285 are formed assubstantially spherical metal balls or other conductive beads orpellets, and incorporated into the base 100G as it is being formed, suchas during a molding process. The plurality of conductive vias 285 maythen be distributed randomly (as illustrated), or periodically orotherwise regularly, within the base 100G. As the base 100G is beingformed, at least some of the plurality of integrally formed conductivevias 285 will make physical contact with both a first conductor 110 andthe conductive backplane 290, thereby providing electrical couplingbetween the first conductors 110 and the conductive backplane 290. Forsuch an exemplary embodiment, a sufficient number of conductive vias 285are provided during fabrication, such that when randomly distributedwithin the base 100G, every first conductor 110 is in contact with atleast one conductive via 285 which also is in contact with theconductive backplane 290. In other exemplary embodiments, the conductivevias 285 are (non-randomly) distributed in predetermined locations, alsoso that every first conductor 110 is in contact with at least oneconductive via 285 which also is in contact with the conductivebackplane 290.

FIG. 11 is a perspective view of an exemplary base 100, 100A, 100B,100C, 100D with a plurality of first conductors 110 and a plurality ofsubstrate particles 120 for an apparatus embodiment in accordance withthe teachings of the present invention. FIG. 12 is a cross-sectionalview (through the 40-40′ plane) of the fifth exemplary base 100D with aplurality of first conductors 110 and a plurality of substrate particles120 for an apparatus embodiment in accordance with the teachings of thepresent invention. Following deposition of the one or more firstconductors 110, the material (such as a conductive ink or polymer) maybe cured or partially cured, to form a solid or semi-solid. In otherembodiments, the one or more first conductors 110 may remain in a liquidor partially-cured form and be cured subsequently. Following thedeposition of the one or more first conductors 110, with any suchcuring, partial curing, or non-curing, a suspension of a plurality ofsubstrate particles 120 is deposited over the one or more firstconductors 110 in the cavities, channels or grooves 105, and (most) forman ohmic contact 265 with a corresponding first conductor 110.

In many exemplary embodiments, the plurality of substrate particles 120are comprised of a semiconductor substrate, such as a p+ silicon or GaNsubstrate, and so may be referred to as a plurality of semiconductorparticles 120. In other exemplary embodiments, the plurality ofsubstrate particles 120 may comprise other organic, inorganic, orpolymeric materials, such as compounds or mixtures suitable for creatingorganic or polymer light emitting diodes, as discussed below, and soalso may be referred to as a plurality of light emitting substrateparticles 120 or photovoltaic substrate particles 120. A wide variety ofsuitable types of substrates for use as substrate particles 120 arediscussed in greater detail below. Accordingly, any reference herein toa plurality of substrate particles 120 or, equivalently, a plurality ofsubstrate (semiconductor) particles 120 should be understood to mean andinclude any organic or inorganic substrate in a particulate form of somekind which is suitable for use in light emitting, photovoltaic, or otherelectronic applications of any kind, currently known or developed in thefuture, with any and all such substrates considered equivalent andwithin the scope of the claimed invention.

The suspension of a plurality of substrate particles 120 may bedeposited, for example, through a printing or coating process, such asby printing within the plurality of cavities 105 having the plurality offirst conductors 110, or by printing over a first conductor 110 whichhas been deposited as a layer (FIGS. 34-40) or sheet. As illustrated inFIGS. 37-40, a conductive adhesive 110A has been deposited prior todeposition of the substrate particles 120, as another mechanism forbonding an created ohmic contacts between the substrate particles 120and the one or more first conductors 110. Also for example, thesuspension of a plurality of substrate particles 120 may be coated overthe base 100, 100A, 100B, 100C, 100D, 100E, 100F, 100G, 100H andplurality of first conductors 110, with any excess removed using adoctor blade or other scraping process, as previously described.

For example and without limitation, the plurality of substrate particles120 may be suspended in a liquid, semi-liquid or gel carrier using anyevaporative or volatile organic or inorganic compound, such as water, analcohol, an ether, etc., which may also include an adhesive component,such as a resin, and/or a surfactant or other flow aid. In an exemplaryembodiment, for example and without limitation, the plurality ofsubstrate particles 120 are suspended in deionized water as a carrier,with water soluble thickeners such as methyl cellulose, guar gum orfumed silica (such as Cabosil), may also utilize a surfactant or flowaid such as octanol, methanol, isopropanol, or deionized octanol orisopropanol, and may also use a binder such as an anisotropic conductivebinder containing substantially or comparatively small nickel beads(e.g., 1 micron) (which provides conduction after compression and curing(as discussed below) and may serve to improve or enhance creation ofohmic contact 265, for example), or any other uv, heat or air curablebinder or polymer, including those discussed in greater detail below(and which also may be utilized with dielectric compounds, lenses, andso on). The volatile or evaporative components are dissipated, such asthrough a heating, uv cure or any drying process, for example, to leavethe substrate particles 120 substantially or at least partially incontact with and adhering to the one or more first conductors 110. Thesuspending material may also include reflective, diffusing or scatteringparticles, for example, to aid in light transmission in a directionnormal to a base 100, 100A, 100B, 100C, 100D, 100E, 100F, 100G, 100H forlight emitting applications.

Additional steps or several step processes may also be utilized fordeposition of the plurality of substrate particles 120 over theplurality of first conductors 110 and within the cavities, channels orgrooves 105. Also for example and without limitation, a binder such as amethoxylated glycol ether acrylate monomer (which may also include awater soluble photoinitiator such TPO (triphosphene oxides)) or ananisotropic conductive binder may be deposited first, followed bydeposition of the plurality of substrate particles 120 which have beensuspended in any of the carriers discussed above.

For example, when the plurality of first conductors 110 have only beencured partially or are uncured when the plurality of substrate particles120 are deposited, the plurality of substrate particles 120 may becomeslightly or partially embedded within the plurality of first conductors110, helping to form an ohmic contact 265, as illustrated in the variousFigures. Additional embedding or contact creation may also occur throughan application of pressure (as discussed below with reference to FIG.13), thermal (heat) processing, uv curing, etc.

In an exemplary embodiment, the suspending medium for the plurality ofsubstrate particles 120 also comprises a dissolving or other reactiveagent, which initially dissolves or re-wets some of the one or morefirst conductors 110. When the suspension of the plurality of substrateparticles 120 is deposited and the surfaces of the one or more firstconductors 110 then become partially dissolved or uncured, the pluralityof substrate particles 120 may become slightly or partially embeddedwithin the one or more first conductors 110, also helping to form anohmic contact 265, and creating a “chemical bonding” or “chemicalcoupling” between the plurality of substrate particles 120 and the oneor more first conductors 110. As the dissolving or reactive agentdissipates, such as through evaporation, the plurality of firstconductors 110 re-hardens (or re-cures) in substantial contact with theplurality of substrate particles 120. An exemplary dissolving orreactive agent, for example and without limitation, is proplyene glycolmonomethyl ether acetate (C₆H₁₂O₃) (sold by Eastman under the name “PMAcetate”), used in an approximately 1:8 molar ratio (or 22:78 by weight)with isopropyl alcohol (or isopropanol) to form the suspending mediumfor the plurality of substrate particles 120. Other exemplary dissolvingor reactive agents, also for example and without limitation, include avariety of dibasic esters, and mixtures thereof, such as dimethylsuccinate, dimethyl adipate and dimethyl glutarate (which are availablein varying mixtures from Invista under the product names DBE, DBE-2,DBE-3, DBE-4, DBE-5, DBE-6, DBE-9 and DBE-IB). In an exemplaryembodiment, DBE-9 in an approximately 1:10 molar ratio with isopropanolalso has been utilized.

The plurality of substrate particles 120 may be comprised of any type ofsemiconductor element, material or compound, such as silicon, galliumarsenide (GaAs), gallium nitride (GaN), or any inorganic or organicsemiconductor material, and in any form, including GaP, InAlGaP,InAlGaP, AlInGaAs, InGaNAs, AlInGASb, for example and withoutlimitation. For example, to form semiconductor substrate particles 120,silicon may be utilized as a monocrystal, as polysilicon, amorphoussilicon, and so on, and does not require the epitaxial crystal growth ofsemiconductor integrated circuits and conventional diodes, with asimilar variety of crystal structures and amorphous forms also availablefor gallium arsenide, gallium nitride, and other semiconductorcompounds. The plurality of substrate particles 120 also may becomprised of any type of organic or inorganic compound or polymerutilized for light emission or energy absorption (photovoltaics), suchas the various polymers and compounds utilized for light emitting diodes(“OLEDs”), phosphorescent OLEDs (“PHOLEDs”), polymer light emittingdiodes (“PLEDs”), light emitting polymers (“LEPs”), including forexample and without limitation polyacetylene compounds, polypyrrolecompounds, polyaniline compounds, poly(p-phenylene vinylene),polyfluorene, conjugated dendrimers, organo-metallic chelates (e.g.,Alq3), and any and all of their corresponding derivatives, substitutedside chains, etc., which also may have encapsulated forms, such asencapsulated in a micelle or other container. As mentioned above,“substrate particles” may include any inorganic or organicsemiconductor, energy emitting, energy absorbing, light emitting,photovoltaic, or other electronic material, and any and all suchelements, compounds, mixtures and/or suspensions are within the scope ofthe claimed invention.

In FIGS. 11-24 and 32-40, the substrate particles 120 are illustrated asbeing substantially spherical. In addition, while the substrateparticles 120 (and diodes 155 and lenses 150) are or may be referred toas “spherical” for one or more exemplary embodiments, it should beunderstood that as used herein, “spherical” means and includes“substantially spherical”, i.e., substantially or mostly spherical tothe extent of being within a predetermined or other selected variance,tolerance or other specification, as virtually no actual object isperfectly spherical in a theoretical or textbook sense. For example andwithout limitation, the various spherical particles (substrateparticles, diodes, lenses) utilized in the exemplary embodimentstypically will lack at least some uniformity (1) within each such sphere(i.e., there will be some variation in its radius from the center todifferent points of the surface, and will be slightly aspherical to somedegree), (2) from sphere to sphere, with variations in sizes of spheres,(3) in the various shapes and sizes of particles, with some or manybeing substantially spherical (and others significantly asphericaland/or misshapen, depending upon the tolerances of the supplier, forexample), and (4) in surface properties, with substrate particles 120having substantially smooth or polished surfaces and others having moresurface variation or roughness. The substrate particles 120 may beformed as spherical particles, beads or pellets as known or becomesknown in the art, such as disclosed for silicon (semiconductor)particles in Hamakawa et al. U.S. Pat. No. 6,706,959, issued Mar. 16,2004, entitled “Photovoltaic Apparatus and Mass-Producing Apparatus forMass-Producing Spherical Semiconductor Particles”, which is incorporatedby reference herein with the same full force and effect as if set forthin its entirety herein. Other aspherical or otherwise irregularsubstrate particles may be formed into substantially spherical substrateparticles through any of various types of polishing methods, such as ina ball mill, for example and without limitation.

In various exemplary embodiments, the plurality of substrate particles120 are subsequently converted in situ into corresponding diodes 155, asdiscussed in greater detail below. Accordingly, the plurality ofsubstrate particles 120 are sized to provide one or more selected sizesof the resulting plurality of diodes 155, such as resulting diodes 155in the range of about 10-40 microns (μm), for example, which isconsiderably smaller (by orders of magnitude) than prior art lightemitting or photovoltaic diodes. In another exemplary embodiment, thediodes 155 are in the range of about 25-40 microns (μm), also forexample and without limitation. Use of such small substrate and diodesizes are possible due to the novel methods of manufacturing herein,including the use of suspensions of the plurality of substrate particles120 and the use of deposition techniques such as printing, which allowhandling of the substrate particles as a group, en masse, rather thanrequiring individual placement of each particle 120. In addition, alsoas discussed in greater detail below, the very small size of theresulting diodes 155 is especially advantageous, providing an increasedamount of a (pn) junction per amount of substrate material, enablinghigher efficiencies of light output (for LED applications) or conversionof light into electrical energy (for photovoltaic applications).

In various exemplary embodiments, the plurality of substrate particles120 are selected or designed to have a shape which facilitates orcreates optical resonance at one or more selected frequencies, such assubstantially spherical, substantially toroidal (or ring) shaped,cylindrical or rod shaped, etc., and which are referred to individuallyand collectively herein as substantially optically “resonant” diodes 155and/or semiconductor or substrate particles 120. In addition, aplurality of substrate particles 120 may also be selected or designed tohave a shape which may facilitate mode coupling with the plurality oflenses 150, as discussed in greater detail below.

In other exemplary embodiments, the plurality of substrate particles 120may have other shapes and forms, such as faceted, oblong (elliptical),substantially rectangular, substantially flat, or substantiallyirregular or aspherical, as illustrated in FIGS. 26-31, for example andwithout limitation. For example, faceted substrate particles 120 may beuseful for light emission. Also for example, a substantially rectangularor substantially flat substrate particles 120, such as the shape andsize of a prior art, conventional diode, may also be utilized inselected exemplary embodiments. In addition, the plurality of substrateparticles 120 may have any of myriad sizes and shapes, with a variety ofsizes utilized, such as to provide emission, absorption or opticalresonance at a plurality of wavelengths of light or otherelectromagnetic (EM) waves. For example and without limitation, in anexemplary embodiment, the substrate particles 120 are substantiallyspherical (within a predetermined tolerance) and in a range of about10-40 microns, and potentially in the range of about 25-40 or 25-30microns. In an exemplary embodiment, silicon, GaAs or GaN is utilizedwhich has been doped (e.g., with Boron or another element) to be a p orp+ (equivalently referred to as P or P+) semiconductor, to facilitateforming corresponding ohmic contacts with the one or more firstconductors 110. In other embodiments, n or n+ (equivalently referred toas N or N+) dopant levels also may be utilized.

Of special interest, it should be noted that other than suspending theminto a carrier (a suspending medium), the plurality of substrateparticles 120 do not require any processing prior to depositing themover the one or more first conductors 110 in the plurality of cavities,channels or grooves 105. For example, the plurality of substrateparticles 120 do not require any micromachining to change their shape orto expose interior portions, in sharp contrast to the prior art.

In addition, at this point in the process of creating an apparatus (200,300, 400, 500, 600 and/or 700), the plurality of substrate particles 120are substantially isotropic and do not have and do not require anyorientation during or prior to depositing them over the one or morefirst conductors 110 (in the plurality of cavities, channels or grooves105). Rather, also in sharp contrast with the prior art, an orientationor difference in the substrate (e.g., semiconductor) material is createdsubsequently when the plurality of substrate particles 120 are formedinto diodes in situ, with the subsequent formation of a corresponding pn(or equivalent) junction in a substrate (e.g., semiconductor) particle120 which has already been fixed in place during the manufacturing andcreation of an apparatus 200, 300, 400, 500, 600, 700

As an option, provided sufficient ohmic contacts may be created betweenthe plurality of substrate particles 120 and the one or more firstconductors 110, the carrier or suspending material for the plurality ofsubstrate particles 120 may also include an insulating (or dielectric)binder or other polymer, which may be comprised of any curable compoundhaving a reasonably high dielectric constant sufficient to provideelectrical insulation between the plurality of first conductors 110 andthe plurality of second conductors 140 discussed below. As discussed ingreater detail below, a wide variety of dielectric compounds may beutilized, any and all or which are within the scope of the presentinvention, and may be included within air, heat- or uv-curable bindersor other polymers, for example, to form part or all of the suspendingliquid, semi-liquid or gel carrier.

Those having skill in the art will also recognize that various removableor etchable compounds may also be utilized. For example, once theplurality of substrate particles 120 have been embedded within or makesufficient electrical contact with the plurality of first conductors110, followed by curing, all or part of the suspending material orbinder may be removed, such as through an acid or ion etching process.Such an etching or washing process may also facilitate providingadditional electrical contacts with the plurality of semiconductorspherical particles 120, such as the subsequent formation of electricalcontacts with the one or more second conductors 140.

In another variation, the substrate particles 120 are suspended in acarrier such as an organic or inorganic solvent. The carrier is thenallowed to evaporate, such as through the application of heat, air, orother methods to facilitate evaporation, and the plurality of substrateparticles 120 are bonded to the one or more first conductors 110, suchas through use of a dissolving or reactive agent (as discussed above),pressure, laser, uv or thermal annealing or alloying, or anotherapplication of energy in some form. Accordingly, electrical couplingbetween the plurality of substrate particles 120 and the one or morefirst conductors 110 may occur in any of a plurality of ways, any andall of which are within the scope of the claimed invention. For exampleand without limitation, such coupling may occur by abutment, pressure,laser, uv or thermal annealing or alloying, by partially embedding theplurality of substrate particles 120 within one or more first conductors110 (such as when the conductive ink or polymer forming the one or morefirst conductors 110 was uncured or only partially cured prior todepositing the plurality of substrate particles 120, or has beendissolved or re-wetted using a reactive suspending agent during thesubstrate particle deposition process), or by using anisotropicconductive polymers, which create an electrical connection followingcompression and curing, for example and without limitation. In anexemplary embodiment, the substrate particles 120 are annealed with orto one or more aluminum-based first conductors 110 through thermalannealing between about 350-450 degrees C. or any lower temperaturesufficient for forming a desired or selected degree of ohmic contact(s)without adversely affecting other parts of the device, such as dependingupon the composition of the base 100.

FIG. 13 is a lateral view of the fifth exemplary base 100D with theplurality of substrate particles 120 passing through compressive rollers195 for an optional step in an exemplary method of forming an apparatusembodiment in accordance with the teachings of the present invention. Insuch an exemplary embodiment, the plurality of first conductors 110 mayremain in a liquid, gel, or partially-cured form. Following depositionof the plurality of substrate particles 120, the plurality of substrateparticles 120 may be pressed into the uncured or partially curedplurality of first conductors 110, such as by moving the base 100, 100A,100B, 100C, 100D, 100E, 100F, 100G and/or 100H having the plurality offirst conductors 110 and the plurality of substrate particles 120through such compressive rollers 195, or any other means of applyingpressure to or seating the plurality of substrate particles 120 in oragainst the plurality of first conductors 110 to help form an ohmiccontact (265) between a semiconductor particle 120 and a first conductor110.

FIG. 14 is a cross-sectional view (through the 40-40′ plane) of thefifth exemplary base 100D with a plurality of first conductors 110 and aplurality of substrate particles 120 having a junction 275 formedtherein and thereby comprising diodes 155 for an apparatus embodiment inaccordance with the teachings of the present invention. Forsemiconductor substrate particles 120, the junction 275 is generally apn (or PN) junction 275, while for organic or polymer substrateparticles 120, the junction 275 may be considered a junction between theorganic or polymer layers utilized to create OLEDs or PLEDs, for exampleand without limitation. As an example, for a plurality of substrateparticles 120 comprising a semiconductor having a first majority carrier(e.g., p+ or n+), a layer or region 255 is created which has a secondmajority carrier (e.g., correspondingly n+ or p+), forming junction 275.As part of a printing process, for a p or p+ semiconductor substratetype, an n-type dopant, such as a phosphorus or phosphorous and siliconin a carrier or binder, is deposited in a liquid, semi-liquid, gel, orfilm form, such as an ink or polymer, to a first or upper portion of theplurality of substrate particles 120, and heated, or subject to laserenergy, or subject to another form of curing, annealing or alloying,such that the n-type dopant or n-type material diffuses into or bondswith the upper portion of the plurality of substrate particles 120 to asufficient degree, forming a penetration layer or region 255 which, inthis case, is an n-type penetration layer or region 255 which defines acorresponding junction 275 (in this case, a pn junction 275) with ap-type semiconductor substrate particle 120. In an exemplary embodiment,the (n-type) penetration layer or region 255 (and corresponding pnjunction 275) is substantially curved and shell-shaped, such ashemispherical shell-shaped when the plurality of substrate particles 120are substantially spherical, with the n-type layer 255 (andcorresponding pn junction 275) typically extending slightly below thelevel of the outer coating 260, and is in sharp contrast to typicalprior art diodes having a substantially planar and flat pn junction or asubstantially planar and flat pn junction within a well of asemiconductor substrate. Conversely, a p-type penetration layer orregion 255 may be formed within an n-type semiconductor particle 120,and is considered equivalent and also within the scope of the presentinvention. Also in an exemplary embodiment, an n-type dopant, such as aphosphorus, is suspended in a comparatively volatile carrier or binderwhich then dissipates upon the application of laser energy. A rapidlaser pulse is utilized, or heat applied (such as with a tungstenheating element or bar or uv lamps, at 800-1200 degrees C. for a periodof time which may be a few tenths of a second up to 15-30 minutes,) onthe first or top portion of the plurality of substrate particles 120,such that any heat dissipates quickly without adversely affecting otherportions of the device. In exemplary embodiments, a resist may also beutilized, such that the remaining portions of the apparatus are notexposed to the deposited dopant material or the deposited dopantmaterial does not adhere to those regions. In addition, various surfacecharacteristics (such as wetting) may also be adjusted, as discussedabove.

In another exemplary embodiment, various “spin-on” materials may bedeposited, through spinning, spraying or printing, to provide suchn-type doping. For such an embodiment, a film of phosphorus, arsenic, orantimony doped glass, for example and without limitation, is depositedon the surface of the plurality of substrate particles 120, such assilicon particles, and heated, either forming an additional layer over(and a pn junction at the interface with) the substrate particles 120(as illustrated in FIG. 15), or causing diffusion to occur from thisfilm into the plurality of semiconductor (silicon) particles 120.Exemplary n-type dopants or spin-on materials include, for example andwithout limitation, dopants available from the Emulsitone Company ofWhippany, N.J., USA, such as Emulsitone Emitter Diffusion Source N-250,Arsenosilicafilm and Antimonysilicafilm for buried layers,Phosphorosilicafilm 5×10²⁰, and Phosphorofilm for solar cells. Theseexemplary dopants or spin-on materials are deposited, and depending onthe application and dopants, such as for Emulsitone Emitter DiffusionSource N-250, may be initially heated to 150-200 degrees C. for 15minutes to harden the film, followed by heating at 800-1200 degrees C.for 15-30 minutes or any lower temperature capable of forming a junction275 and/or layer or region 255 degree with the desired or selectedcharacteristics (such as a desired penetration depth) and withoutadversely affecting other parts of the device at that point in itsmanufacture, such as temperatures as low as or lower than 200-300degrees C.

FIG. 15 is a cross-sectional view of a fifth exemplary base 100D with aplurality of first conductors 110 and a plurality of substrate particles120 following deposition of a layer or region 255A, which also forms ajunction 275, and thereby comprising diodes 155 for an apparatusembodiment in accordance with the teachings of the present invention,and serves to illustrate another variation for the manufacture of diodes155 in situ, also in accordance with the teachings of the presentinvention. For such an exemplary embodiment, a diode 155 comprises alayer or region 255A coupled to a substrate particle 120 to form ajunction 275. (FIG. 15 may also be considered a variation of across-sectional view (through the 40-40′ plane) of FIG. 12, followingdeposition of one or more insulators 135 and a layer or region 255A,which is not separately illustrated in a perspective view. FIG. 15 mayalso be considered a variation of a cross-sectional view (through the50-50′ plane) of FIG. 16, following deposition of a layer or region255A, which also is not separately illustrated in a perspective view.)

As discussed in greater detail below with reference to FIGS. 16 and 17,one or more insulators (or insulating layers) 135 may be deposited, toprovide electrical isolation between one or more second conductors 140and one or more first conductors 110. For this exemplary embodiment,following deposition of the plurality of substrate particles 120, one ormore insulators (or insulating layers) 135 may be deposited, followed bydeposition of a layer or region 255A. In other exemplary embodiments,the one or more insulators (or insulating layers) 135 may be depositedafter the in situ creation of diodes 155, as discussed below.

Also as an example, for a plurality of substrate particles 120comprising a semiconductor having a first majority carrier (e.g., p+ orn+), a layer or region 255A is created which has a second majoritycarrier (e.g., correspondingly n+ or p+), also forming junction 275. Forsemiconductor substrate particles 120, the junction 275 is generally apn (or PN) junction 275, while for organic or polymer substrateparticles 120, the junction 275 may be considered a junction between theorganic or polymer layers utilized to create OLEDs or PLEDs, for exampleand without limitation. As part of a deposition process, such as usingplasma deposition or sputtering, for semiconductor substrate type havinga first majority carrier (e.g. p+ silicon), a semiconductor materialhaving a second majority carrier (e.g., an n-type dopant, such as aphosphorus-doped silicon) is deposited over (on top of) a first or upperportion of the plurality of substrate particles 120 and any one or moreinsulators 135. In addition, in various embodiments, the semiconductormaterial having a second majority carrier may be deposited over thefirst surface (or side), covering a first or upper portion of theplurality of substrate particles 120, one or more insulators 135, andridges or crests 115 (illustrated as region 277). The correspondingdeposited second majority carrier (n-type) semiconductor material formsa continuous semiconductor body with each of the substrate particles120, such as forming a continuous crystal or other bond with the upperportion of a substrate particle 120, forming a deposited layer or region255A which, in this case, is an n-type layer or region 255A whichdefines a corresponding junction 275 (in this case, a pn junction 275)with a first majority carrier (p-type) semiconductor substrate particle120. In an exemplary embodiment, the (n-type) layer or region 255A (andcorresponding pn junction 275) is formed as a “cap” over the substrateparticle 120, and is also substantially curved and shell-shaped, such ashemispherical shell-shaped when the plurality of substrate particles 120are substantially spherical, and also is in sharp contrast to typicalprior art diodes having a substantially planar and flat pn junction or asubstantially planar and flat pn junction within a well of asemiconductor substrate. In another embodiment, when the second majoritycarrier (n-type) semiconductor material is deposited as a layer whichalso covers the insulators 135 and ridges 115, the junction 275 is alsoformed as a “cap” at the interface with the substrate particle 120, andis also substantially curved and shell-shaped, such as hemisphericalshell-shaped when the plurality of substrate particles 120 aresubstantially spherical. Conversely, a first majority carrier (p-type)layer or region 255A may be formed over a second majority carrier(n-type) semiconductor particle 120, and is considered equivalent andalso within the scope of the present invention. Following deposition ofone or more insulators 135 and formation of layers or regions 255A, oneor more second conductors 140 and other features and elements may bedeposited as discussed below (beginning with FIG. 18 and following). Anexemplary apparatus 700 embodiment created using this methodology isillustrated and discussed below with reference to FIGS. 37-40.

In an exemplary embodiment, a layer or region 255A may be depositedusing a plasma deposition process, such as using a vacuum chamber havinga few Torrs, which may be process chamber that is a module of an overallprinting process, for example and without limitation. After depositionof one or more insulators 135 (described in greater detail below), thefirst side or surface may be treated, such as with a gas containingfluorine, which may slightly etch the plurality of substrate particles120 when comprised of a semiconductor such as a doped silicon, and whichmay further create a surface of the insulators 135 which hascomparatively poor adhesion characteristics (e.g., Teflon-like). Theplasma deposition process then deposits the semiconductor material, suchas silicon, which adheres to the first majority carrier substrateparticles 120, but does not substantially adhere to the fluorinatedsurface of the insulators 135 (and can be removed subsequently), anddeposits the second majority carrier (n-type), which becomesincorporated into the deposited semiconductor material and may alsofurther diffuse into the substrate particles 120, forming layer orregion 255A. The deposited, second majority carrier (n-type) dopedsemiconductor material is then in intimate contact with the substrateparticles 120 having the first majority carrier, forming a continuoussemiconductor (e.g., silicon) body having a junction 275, such as a n+pjunction.

In another exemplary embodiment, a layer or region 255A may be depositedusing a sputtering process. After deposition of one or more insulators135 (described in greater detail below), the first side or surface maybe cleaned or treated, such as using a back sputtering process. Thesputtering process then deposits the semiconductor material doped with asecond majority carrier, such as phosphorus-doped silicon from an n+silicon source, which adheres to the first majority carrier substrateparticles 120, the insulators 135, and ridges 115, with the secondmajority carrier (e.g., n-type) incorporated into the depositedsemiconductor material, forming layer or region 255A. The deposited,second majority carrier (n-type) doped semiconductor material is then inintimate contact with the substrate particles 120 having the firstmajority carrier, forming a continuous semiconductor (e.g., silicon)body having a junction 275, such as a n+p junction.

In exemplary embodiments, for both the plasma deposition and sputterprocesses, a resist may also be utilized, such that the remainingportions of the apparatus are not exposed to the deposited dopantmaterial or the deposited dopant material does not adhere to thoseregions. In addition, various surface characteristics (such as wetting)may also be adjusted, as discussed above.

Referring to both FIGS. 14 and 15, in various or selected exemplaryembodiments, the (pn) junction 275 may encompass varying percentages ofa shell region about the plurality of substrate particles 120. Forexample, using percentages based upon the amount of surface area coveredby a penetration layer or region 255 forming a corresponding junction275, when the plurality of substrate particles 120 are substantiallyspherical, each substantially hemispherical, shell-shaped (pn) junction275 may encompass 15-60 percent of a semiconductor particle 120; inother exemplary embodiments, a shell-shaped pn junction 275 mayencompass 15-55 percent of a semiconductor particle 120; and in variousexemplary embodiments of substantially spherical substrate particles120, may encompass about or approximately 20-50 percent, or 30-40percent (plus or minus some small percentage (Δ)) of a semiconductorparticle 120. This is also in sharp contrast to the prior art, in whichthe (pn) junction initially covers the entire spherical semiconductor,which subsequently requires micromachining to expose one of thesubstrate types. For example, in an exemplary embodiment, about 15percent to 55 percent of each diode surface and correspondingpenetration or diffusion region (255, 255A) of substantially all of theplurality of substantially spherical diodes has a second majoritycarrier (second dopant type) (n-type or p-type) (i.e. has the seconddopant type over part, most or all of a first, primarily upper surfaceof each diode 155, with the potential for some additional diffusion ofthe second dopant type to the second, lower surface of the diode), andthe remaining diode surface and interior has a first majority carrier(or first dopant type) (p-type or n-type) (i.e., most, part or all of asecond, lower surface of each diode comprises the original substratethat has not been covered by the deposited second dopant type andcorresponding diffusion), with a pn junction formed correspondinglywithin each such substantially spherical diodes.

Because the (n-type) penetration layer or region 255 does not fullyencompass the semiconductor substrate particle 120, no furtherprocessing is needed to expose a p-type region, also in contrast withthe prior art. Accordingly, ohmic contacts with a p-type (or n-type)region may be made directly on the unaltered, non-recessed, exterior ofthe semiconductor substrate particle 120, without any need formicromachining and exposing an interior, recessed portion. In addition,because the resulting diode 155 has been created in situ, no alignmentof the pn junction and no placement of an oriented diode is required,with proper alignment and placement occurring automatically due to thenovel method of manufacturing a diode 155 in place within an exemplaryapparatus 200, 300, 400, 500, 600 and/or 700. Furthermore, ohmiccontacts between the substrate particles 120 and the one or more firstconductors 110 have been created prior to diode 155 formation, also insharp contrast to typical semiconductor fabrication techniques.Accordingly, a junction 275 has been created in a diode 155 which issubstantially curved and shell-shaped (and, for exemplary embodiments,substantially hemispherically shell-shaped or cap-shaped), and furthersimultaneously or concurrently having an “exposed” semiconductorsubstrate (e.g., a p-type region bonded or available for bonding to aconductor) and, for exemplary embodiments, an exposed and substantiallyhemispherically-shaped semiconductor substrate, which at least in parthas already been coupled to one or more first conductors 110. Statedanother way, a (pn) junction 275 has been created which is substantiallycurved and shell or cap-shaped (which covers a predetermined percentageof the semiconductor substrate particle 120 and which does not, at anytime, encompass an entire semiconductor substrate particle 120), in asemiconductor substrate particle 120 which has already been bonded,attached or otherwise coupled to a conductor such as a first conductor110.

Following diode 155 creation (with either a region or layer 255 or255A), a passivating or passivation layer may be formed, such as using aplasma deposition process, creating a comparatively tough and durablecoating on the diodes 155, which in various embodiments, may also beflexible. For example, plasma deposition may be utilized to

In various exemplary embodiments, as mentioned above, the plurality ofsubstrate particles 120 are sized to provide one or more selected sizesof the resulting plurality of diodes 155, such as resulting diodes 155in the range of about 10-40 or 25-40 microns (μm), for example. Thisvery small size of the resulting diodes 155 is especially advantageous,providing an increased amount of a (pn) junction 275 per amount ofsubstrate material, enabling higher efficiencies of light output (forLED applications) or conversion of light into electrical energy (forphotovoltaic applications), among other things.

In addition, for photovoltaic applications, when the plurality ofsubstrate particles 120 are substantially spherical, it is alsosignificant that the pn junction 275 that has been formed is or will begenerally fully exposed to (and in some cases normal to) the incidentlight, coming from any corresponding direction on the first or upperportion of the apparatus 200, 300, 400, 500, 600, 700. This additionalfeature enables incoming light from a wide variety of directions to beutilized for energy generation, without an additional prior artrequirement of moving or orienting photovoltaic panels to track solarmovement or locations (using the earth as a frame of reference).

When the plurality of substrate particles 120 are comprised of organicor inorganic compounds and polymers (such as those utilized for OLEDs orPLEDs), there are additional available variations. Depending upon thetype of compound utilized, the OLED may be comprised of a single layer,in this case the substrate particle 120, and, if so, the formation oflayer 255 is not required. For other, multiple layer OLEDs, theformation of layer or region 255 may be accomplished by the coating,printing, or other addition of the compounds and/or polymers utilizedfor the selected OLED and/or OLED layer, with the layer 255 thencomprising the corresponding OLED layer, and with a correspondinginter-layer junction (275) formed (comparable or equivalent to a pnjunction, for example) (and with the organic substrate particles alsobecoming corresponding (organic) diodes 155, also for example and asdiscussed below). For multiple layer OLEDs, this process may berepeated, creating a plurality of regions 255, one on top of the other,also forming an OLED in position in an exemplary apparatus 200, 300,400, 500, 600, 700 and after coupling the substrate particle 120 to aconductor (first conductor 110).

Through this use of deposited carriers (dopants) and/or coatings, over aplurality of substrate particles 120, with the formation of a pn orequivalent junction in situ, the plurality of substrate particles 120have now been converted into a corresponding plurality of diodes 155,and may be any type or kind of diode, such as for photovoltaic (“PV”diodes) applications or for light emitting applications (light emittingdiodes or “LEDs”). Stated another way, when deposited, the substrateparticles 120 are not diodes, but are just substrate particles withoutjunctions, followed by forming the junctions 275 in place.

In addition, in exemplary embodiment, substrate particles 120 andcorresponding dopants and coatings, to form light emitting diodes(“LEDs”), may be differentially deposited, such as printing a firstrow/cavity of red LEDs, a second first row/cavity of green LEDs, a thirdfirst row/cavity of blue LEDs, a fourth first row/cavity of red LEDs,etc., creating a light emitting apparatus having control over colortemperature, for example and without limitation. As mentioned above,connections or couplings, such as wires or leads, may be connected tocorresponding vias 280, 285, without a conductive backplane 290, toprovide the capability for individual selection of such rows, throughthe application of a corresponding voltage or current. As described ingreater detail below with reference to FIG. 20, additional coatings mayalso be utilized, such as coatings of one or more types of phosphors forLED applications.

FIG. 16 is a perspective view of an exemplary base 100, 100A, 100B,100C, 100D with a plurality of first conductors 110, a plurality ofdiodes 155, and a plurality of insulators 135 having been deposited foran apparatus embodiment in accordance with the teachings of the presentinvention. FIG. 17 is a cross-sectional view (through the 50-50′ plane)of the fifth exemplary base 100D with a plurality of first conductors110, a plurality of diodes 155, and a plurality of insulators 135 havingbeen deposited for an apparatus embodiment in accordance with theteachings of the present invention. As an option, an insulating materialhas been deposited over the peripheral or lateral portions of the first(top or upper) portions of the plurality of diodes 155 to form acorresponding plurality of insulators 135, such as through a printing orcoating process, prior to deposition of a plurality of second conductors140 or a single second conductor 140 (e.g., a second conductive layer),or may be deposited as a single, continuous insulating layer (asillustrated and discussed below with reference to FIGS. 34, 35 and 36).The optional insulators 135 may be utilized to help prevent any contactbetween a second conductor 140 and the second or lower (in this case,p-type) portion of a diode 155. In addition, in exemplary embodiments,an insulator 135 may be deposited as a layer, provided enough of thediodes 155 remain exposed both for contact with one or more secondconductors 140 and exposure of the first, upper portions of the diodes155 for light emission or absorption. As mentioned above with referenceto FIG. 15, one or more insulators 135 may also be deposited prior todiode 155 creation.

In addition, the plurality of insulators 135 may be comprised of any ofthe insulating or dielectric compounds suspended in any of variousmedia, as discussed above and below, such as inorganic dielectricparticles suspended in a polymeric media having a photoinitiator, forexample and without limitation. In the illustrated embodiments, one ormore dielectric suspensions, of inorganic dielectric particles suspendedin polymeric media having a photoinitiator, such as a uv-curablepolymeric binder, are deposited separately from or in addition to theplurality of substrate particles 120 to form one or more insulators 135.Exemplary dielectric compounds utilized to form an insulating (ordielectric) suspension include, for example and without limitation:organic or inorganic dielectric particles (e.g., barium titanate,titanium dioxide, in powder or other particulate form, etc.) suspendedin solvents or polymers such as deionized water, diethylene glycol,isopropanol, butanol, ethanol, PM acetate (propylene glycol monomethylether acetate), dibasic esters (e.g., Invista DBE-9); water solubleresins such as polyvinyl alcohol (“PVA”), polyvinyl butyral (“PVB”),polyvinyl pyrrolidone, polyethylene glycol; and flow aids or surfactantssuch as octanol and Emerald Performance Materials Foamblast 339, forexample. In other exemplary embodiments, one or more insulators 135 maypolymeric, such as comprising PVA or PVB in deionized water, typicallyless than 12 percent. Other commercially available, exemplary dielectriccompounds utilized to form an insulating (or dielectric) suspension,polymer, or carrier include, without limitation: (1) from ConductiveCompounds, a barium titanate dielectric; (2) from DuPont, 5018A Clear UVCure Ink, 5018G Green UV Cure Ink, 5018 Blue UV Cure Ink, 7153 High KDielectric Insulator, and 8153 High K Dielectric Insulator; (3) fromSunPoly, Inc., 305D UV Curable dielectric ink and 308D UV Curabledielectric ink; and (4) from various suppliers, Titanium Dioxide-filledUV curable inks.

FIG. 18 is a perspective view of an exemplary base 100, 100A, 100B,100C, 100D with a plurality of first conductors 110, a plurality ofdiodes 155, a plurality of insulators 135, and a plurality of secondconductors 140 having been deposited for an apparatus embodiment inaccordance with the teachings of the present invention. FIG. 19 is across-sectional view (through the 60-60′ plane) of the fifth exemplarybase 100D with a plurality of first conductors 110, a plurality ofdiodes 155, a plurality of insulators 135 and a plurality of secondconductors 140 having been deposited for an apparatus embodiment inaccordance with the teachings of the present invention.

Referring to FIGS. 18 and 19, following either formation of the pn orother junction 275 and/or deposition of plurality of insulators 135, orvice-versa, one or more second conductors 140 are deposited (e.g.,through printing a conductive ink, polymer, or other conductor such asmetal), which may be any type of conductor, conductive ink or polymerdiscussed above, or may be an optically transmissive (or transparent)conductor, to form an ohmic contact with exposed or non-insulatedportions of the first or upper (in this case, n-type) penetration layeror region (255) of the diodes 155. While illustrated as a plurality ofsecond conductors 140, an optically transmissive second conductor alsomay be deposited as a single continuous layer (forming a singleelectrode), such as for lighting or photovoltaic applications (asillustrated and discussed below with reference to FIGS. 34, 35 and 36).An optically transmissive second conductor(s) 140 may be comprised ofany compound which: (1) has sufficient conductivity to energize orreceive energy from the first or upper portions of the apparatus 200,300, 400, 500, 600, 700 in a predetermined or selected period of time;and (2) has at least a predetermined or selected level of transparencyor transmissibility for the selected wavelength(s) of electromagneticradiation, such as for portions of the visible spectrum. For example,when the present invention is utilized for lighting or photovoltaicapplications, the conductivity time or speed in which a transmissivesecond conductor(s) 140 provides or receives energy to or from theplurality of diodes 155 is comparatively less significant than for otherapplications. As a consequence, the choice of materials to form theoptically transmissive or non-transmissive second conductor(s) 140 maydiffer, depending on the selected application of the apparatus 200, 300,400, 500, 600, 700 and depending upon the utilization of optional one ormore third conductors 145 (discussed below). The one or more secondconductor(s) 140 are deposited over exposed and/or non-insulatedportions of the plurality of diodes 155, and/or also over any of theplurality of insulators 135 and/or ridges 115, such as by using aprinting or coating process as known or may become known in the printingor coating arts, with proper control provided for any selected alignmentor registration, as may be necessary or desirable. Depending upon theselected embodiment, and whether the second conductor 140 issubstantially transparent, the one or more second conductor(s) 140 maybe deposited over all or merely part of the exposed portions of theplurality of diodes 155 and/or any plurality of insulators 135, such asabout the sides or edges of the periphery of the diodes 155, asillustrated.

In an exemplary embodiment, in addition to the conductors describedabove, carbon nanotubes (CNTs), polyethylene-dioxithiophene (e.g., AGFAOrgacon), a polyaniline or polypyrrole polymer, indium tin oxide (ITO)and/or antimony tin oxide (ATO) (with the ITO or ATO typically suspendedas particles in any of the various binders, polymers or carrierspreviously discussed) may be utilized to form optically transmissivesecond conductor(s) 140. In an exemplary embodiment, carbon nanotubesare suspended in a polymerizable ionic liquid, such as an aqueoushydrazine with a polymerizable acrylate or other polymerizable compound(and may further include additional surfactants), with the resultingconductor (110, 140, 145) comprising carbon nanotubes suspended in a(cured) acrylic, plastic or polymer. While ITO and ATO providesufficient transparency for visible light, their impedance or resistanceis comparatively high (e.g., 20 kΩ), generating a correspondinglycomparatively high (i.e., slow) time constant for electricaltransmission. Other compounds having comparatively less impedance mayalso be utilized, such as polyethylene-dioxithiophene. As a consequence,in some of the exemplary embodiments, one or more third conductors 145(illustrated in FIGS. 22, 24, 26, 27, 33, 41) having a comparativelylower impedance or resistance is or may be incorporated intocorresponding transmissive second conductor(s) 140, to reduce theoverall impedance or resistance of this layer, decrease conduction time,and also increase the responsiveness of the apparatus. As indicatedabove, for lighting or photovoltaic applications having larger formfactors, such one or more third conductors 145 may be utilized toprovide more rapid illumination, enabling the energizing of the morecentral portions of the area to be illuminated, which might otherwiseremain non-energized and dark, due to the insufficient conduction ofmany types of compounds which may be selected for use in opticallytransmissive second conductor(s) 140. For example, to form one or morethird conductors 145, one or more fine wires may be formed using aconductive ink or polymer (e.g., a silver ink, CNT or apolyethylene-dioxithiophene polymer) printed over corresponding stripsor wires of the transmissive second conductor(s) 140, or one or morefine wires (e.g., having a grid pattern) may be formed using aconductive ink or polymer printed over a larger, unitary transparentsecond conductor 140 in larger displays, to provide for increasedconduction speed throughout the transparent second conductor 140, and isdiscussed in greater detail in the related applications. Use of suchthird conductors 145 is illustrated in various Figures and discussedfurther below.

Other compounds which may be utilized equivalently to form substantiallyoptically transmissive second conductor(s) 140 include indium tin oxide(ITO) as mentioned above, and other transmissive conductors as arecurrently known or may become known in the art, including one or more ofthe conductive polymers discussed above, such aspolyethylene-dioxithiophene available under the trade name “Orgacon”,and various carbon and/or carbon nanotube-based transparent conductors.Representative transmissive conductive materials are available, forexample, from DuPont, such as 7162 and 7164 ATO translucent conductor.Transmissive second conductor(s) 140 may also be combined with variousbinders, polymers or carriers, including those previously discussed,such as binders which are curable under various conditions, such asexposure to ultraviolet radiation (uv curable).

Referring again to FIGS. 18 and 19, when the first (110) and second(140) conductor(s) are energized, resulting in the provision of power tothe plurality of diodes 155 such as LEDs, light is emitted in thevisible spectrum. The resulting apparatus 200, 300, 400, 500, 600 and/or700 (correspondingly referred to as a light emitting apparatus 200A,300A, 400A, 500A, 600A, 700A), therefore, has particular usefulness forlighting applications and for static display applications. Similarly,when the plurality of diodes 155 are photovoltaic diodes (forming aphotovoltaic apparatus correspondingly referred to as an apparatus 200B,300B, 400B, 500B, 600B and/or 700B), when exposed to light, a voltage isgenerated across the one or more first conductors 110 and the one ormore second conductors 140. As the one or more first conductors 110 arelocated between the diodes 155 and the base (100-100H), thecorresponding voltages may be provided or obtained through theconductive backplane 290, through the conductive vias 280 or 285,through exposed edges of the one or more first conductors 110 about theperiphery of the apparatus 200, 300, 400, 500, 600 and/or 700, orthrough any other connections coupled to the vias 280, 285 or conductors110. Access to the one or more second conductors 140 also may be madethrough exposed edges about the periphery of the apparatus 200, 300,400, 500, 600, or from the first or upper side of the apparatus 200,300, 400, 500, 600, 700.

FIG. 20 is a cross-sectional view of the fifth exemplary base 100D witha plurality of first conductors 110, a plurality of diodes 155, aplurality of insulators 135, a plurality of second conductors 140, andone or more emissive layers 295 (e.g., comprising one or more phosphorlayers or coatings), forming for an apparatus embodiment in accordancewith the teachings of the present invention. In an exemplary embodiment,such as an LED embodiment, one or more emissive layers 295 may bedeposited, such as through printing or coating processes discussedabove, over the diodes 155 (and may also be deposited over otherselected areas or the entire surface). The one or more emissive layers295 may be formed of any substance or compound capable of or adapted toemit light in the visible spectrum (or other electromagnetic radiationat any selected frequency) in response to light (or otherelectromagnetic radiation) emitted from diodes 155. For example, ayellow phosphor-based emissive layer 295 may be utilized with a bluelight emitting diode 155 to produce a substantially white light. Suchelectroluminescent compounds include various phosphors, which may beprovided in any of various forms and with any of various dopants, suchas a zinc sulfide or a cadmium sulfide doped with copper, magnesium,strontium, cesium, rare earths, etc. One such exemplary phosphor is azinc sulfide (ZnS-doped) phosphor, which may be provided in anencapsulated (particulate) form for ease of use, such as themicro-encapsulated ZnS-doped phosphor encapsulated powder from theDuPont™ Luxprint® electroluminescent polymer thick film materials. Whilenot combined with a dielectric in the exemplary embodiments, thisphosphor may also be combined with a dielectric such as barium titanateor titanium dioxide, to adjust the dielectric constant of this layer.The EL compounds or particles forming the one or more emissive layers295 may be utilized in or suspended in a polymer form having variousbinders, and also may be separately combined with various binders (suchas phosphor binders available from DuPont or Conductive Compounds), bothto aid the printing or other deposition process, and to provide adhesionof the phosphor to the underlying and subsequent overlying layers. Theone or more emissive layers 295 may also be provided in eitheruv-curable or heat-curable forms. A wide variety of equivalentelectroluminescent compounds are available, are within the scope of thepresent invention.

A wide variety of equivalent electroluminescent compounds are availableand are within the scope of the present invention, including withoutlimitation: (1) From DuPont, 7138J White Phosphor, 7151J Green-BluePhosphor, 7154J Yellow-Green Phosphor, 8150 White Phosphor, 8152Blue-Green Phosphor, 8154 Yellow-Green Phosphor, 8164 High-BrightnessYellow-Green and (2) From Osram, the GlacierGlo series, including blueGGS60, GGL61, GGS62, GG65; blue-green GGS20, GGL21, GGS22, GG23/24,GG25; green GGS40, GGL41, GGS42, GG43/44, GG45; orange type GGS10,GGL11, GGS12, GG13/14; and white GGS70, GGL71, GGS72, GG73/74. Inaddition, depending upon the selected embodiment, colorants, dyes and/ordopants may be included within any such emissive layer 295. In addition,the phosphors or phosphor capsules utilized to form an emissive layer295 may include dopants which emit in a particular spectrum, such asgreen or blue. In those cases, the emissive layer may be printed todefine pixels for any given or selected color, such as RGB or CMYK, toprovide a color display.

As such one or more emissive layers 295 are utilized for light emittingapplications, they are not separately illustrated in FIGS. 21-40. Thosehaving skill in the art will recognize that any of the devicesillustrated in FIGS. 21-40 may also comprise such one or more emissivelayers 295 coupled to or deposited over the illustrated diodes 155. Forexample and without limitation, as discussed below, a plurality oflenses 150 (suspended in a polymer (resin or other binder) 165) also maybe deposited directly over the one or more emissive layers 295 and otherfeatures, to create any of the various light emitting apparatusembodiments 200A, 300A, 400A, 500A, 600A and/or 700A.

FIG. 21 is a perspective view of an exemplary base 100, 100A, 100B,100C, 100D with a plurality of first conductors 110, a plurality ofdiodes 155, a plurality of insulators 135, a plurality of secondconductors 140, and a plurality of lenses 150 (suspended in a polymer(resin or other binder) 165) having been deposited for an apparatus 200embodiment in accordance with the teachings of the present invention.FIG. 22 is a cross-sectional view (through the 70-70′ plane) of thefifth exemplary base with a plurality of first conductors 110, aplurality of diodes 155, a plurality of insulators 135, a plurality ofsecond conductors 140, a plurality of third conductors 145 (not visiblein FIG. 21 as covered by lenses 150), and a plurality of lenses 150(suspended in a polymer (resin or other binder) 165) having beendeposited for an apparatus 200 embodiment in accordance with theteachings of the present invention. Not separately illustrated, theapparatus (200, 300, 400, 500, 600, 700) may also include one or moreemissive layers 295, and/or may also include a protective coating, suchas a substantially clear plastic or other polymer, for protection fromvarious elements, such as weather, airborn corrosive substances, etc.,or such a sealing and/or protective function may be provided by thepolymer (resin or other binder) 165. (For ease of illustration, FIG. 21illustrates such a polymer (resin or other binder) 165 using the dottedlines to indicate substantial transparency.)

In exemplary embodiments, the plurality of lenses 150 may be comprisedof a borosilicate glass or other silicate glass, or a plastic such aspolystyrene latex, although any of myriad types of materials may beutilized, including without limitation, other types of glass, plastic,other polymers, crystals or polycrystalline silicate glass, and/or mixesof different types of materials, in any shape or size. While illustratedas substantially spherical, the plurality of lenses 150 may also haveother shapes and forms, such as substantially hemispherical, faceted,elliptical (or oblong), irregular, cubic, or various prismatic shapes(e.g., trapezoidal, triangular, pyramidal, etc.), for example andwithout limitation, and may also have any of the variations and/ortolerances discussed above with reference to the plurality of substrateparticles 120, such as with respect to shape, size, etc. The pluralityof lenses 150 (having at least a first index of refraction) aresuspended as particles in a substantially transparent, optically clearpolymer (resin or other binder) 165 (such as various types of urethane,for example and without limitation), which may be uv, heat or aircurable or dryable, also for example and without limitation, and furtherwhich has at least a second, different index of refraction (differentthan the first index of refraction of the plurality of lenses 150).

The plurality of lenses 150 may have a wide variety of spatialrelationships to the plurality of diodes 155, and may have a widevariety of sizes. No particular spatial relationships (e.g., such asregular or irregular spacing, abutting relationships, etc.) should beinferred from FIGS. 21-22 (or the other FIGS. 23, 24, 30-33, 35, and36), particularly as these Figures are not drawn to scale. For example,as mentioned below, the lenses 150 may be considerably larger than thediodes 155, such as five times as large in an exemplary embodiment.

In an exemplary embodiment, a polymer (resin or other binder) 165 orother polymer may be utilized having a viscosity which also may provideat least some spacing between the plurality of lenses 150 and betweenthe plurality of lenses 150 and the diodes 155, such that the pluralityof lenses 150 and plurality of diodes 155 are not in immediate ordirect, abutting contact, but with each lens 150 being surrounded atleast by a thin film or coating of a polymer (resin or other binder)165. In another exemplary embodiment, a comparatively less viscousbinder is utilized, and any, some or all of the plurality of lenses 150and plurality of diodes 155 are allowed to be in direct, abuttingcontact with each other or with other apparatus components (asillustrated in FIG. 31). The polymer (resin or other binder) 165 isconsidered optically clear or transparent (in its cured or dried form)depending on the selected wavelength of interest, such as visible,infrared and ultraviolet light, may be considered optically opaque forother wavelengths, and vice-versa. In addition to various types ofurethane polymers, any and all other polymers, resins or binders(including any incorporated solvents, flow aids, surfactants, etc.) maybe utilized which are substantially transparent at the selectedwavelengths in their cured or dried form and which have an appropriatelyselected second index of refraction for the selected wavelengths,including those discussed previously, for example and without limitationdeionized water, diethylene glycol, isopropanol, butanol, ethanol, PMacetate (propylene glycol monomethyl ether acetate), methoxylated glycolether acrylate monomer (which may also include a water solublephotoinitiator such TPO (triphosphene oxides)), dibasic esters (e.g.,Invista DBE-9); water soluble resins such as polyvinyl alcohol,polyvinyl butyral, polyvinyl pyrrolidone, polyethylene glycol; and flowaids or surfactants such as octanol and Emerald Performance MaterialsFoamblast 339.

Following deposition of the one or more second conductors 145 (and/orthird conductors 145) (and/or one or more emissive layers 295), in anexemplary embodiment, the plurality of lenses 150 suspended in a polymer(resin or other binder) 165 may be deposited, such as through a printingprocess, over the diodes 155 (and/or one or more emissive layers 295),one or more second conductors 145 (and/or third conductors 145), anyexposed base (100-100H), and so on. In another exemplary embodiment, theplurality of lenses 150 are suspended in a polymer (resin or otherbinder) 165 in a sheet, panel or other form and cured, with theresulting sheet or panel then attached to the remainder of the apparatus200, 300, 400, 500, 600 and/or 700 (i.e., over the diodes 155 (and/orone or more emissive layers 295), one or more second conductors 145(and/or third conductors 145), any exposed base (100-100H), and so on),such as through a lamination process, for example and withoutlimitation, and all such variations are within the scope of the claimedinvention.

Accordingly, whether the plurality of lenses 150 suspended in a polymer(resin or other binder) 165 are deposited directly over the diodes 155(and/or one or more emissive layers 295), one or more second conductors145 (and/or third conductors 145), and any exposed base (100-100H), orwhether the plurality of lenses 150 suspended in a polymer (resin orother binder) 165 are formed as a separate structure and subsequentlyattached over the diodes 155 (and/or one or more emissive layers 295),one or more second conductors 145 (and/or third conductors 145), and anyexposed base (100-100H), the combination of the plurality of lenses 150suspended in a polymer (resin or other binder) 165 defines a lens (orlensing) structure 150, 165 having a plurality of indexes (or indices)of refraction, namely, a plurality of lenses 150 having at least a firstindex of refraction and a polymer (resin or other binder) having atleast a second index of refraction. This is also in sharp contrast withthe prior art, in which lens or diffusion panels are comprised of asingular prefabricated material, typically plastic or another polymer,having a single index of refraction, and typically having a lens sizeseveral orders of magnitude larger than the plurality of lenses 150utilized in various exemplary embodiments, as discussed in greaterdetail below (e.g., having a mean diameter between about 40-400microns).

The plurality of lenses 150, particularly when implemented assubstantially spherical lenses, provide several functions, including aconcentrating function, for collection of light and concentrating suchlight on plurality of diodes 155 for higher efficiency coupling forphotovoltaic applications, and also for widening the angle of incidence(or acceptance) for the apparatus 200, 300, 400, 500, 600, 700 and/or200B, 300B, 400B, 500B, 600B, 700B, as light incident from many angleswill nonetheless be focused on the plurality of diodes 155. In addition,the plurality of lenses 150 also perform a dispersion function, forspreading light provided by the plurality of spherical diodes 155(and/or one or more emissive layers 295) when formed to be LEDs 155, forthe apparatus 200, 300, 400, 500, 600, 700 and/or 200A, 300A, 400A,500A, 600A, 700A, for example. Another advantage of the plurality oflenses 150 is that no particular alignment or registration is necessary,that they do not need to have any specific position with respect to thespherical diodes 155, with any given lens 150 either concentrating lightupon or dispersing light from several diodes 155. Indeed, as a measureor indicia of comparative sizes, the ratio of the diameter (or radius)of a spherical lens 150 to the diameter (or radius) of a spherical diode155 has been modeled to be significant from approximately 10:1 to 2:1,with a potentially optimum ratio of 5:1 for comparatively higher or moresignificant mode coupling or otherwise significantly greater lightconcentration (or dispersion). The mean diameter of the plurality ofsubstantially spherical lenses is generally about 20 to 400 microns(corresponding to diodes 155 in about the 10-40 micron range), and moreparticularly is about 80 to 140 microns. The typical or mean diameter(s)of the plurality of diodes 155 (and any space between the ridges (peaks,raised portions or crests) 115 of the exemplary base 100 (or,equivalently, the width of the ridges (peaks, raised portions or crests)115 of the exemplary base 100-100G) may be selected or otherwisepredetermined such that the plurality of lenses 150 may be a specific orpredetermined distance apart from each other and/or to form asubstantially or relatively full layer of lenses 150.

The use of the plurality of lenses 150 to widen the angle of incidencefor incoming light for an apparatus 200, 300, 400, 500, 600, 700 isparticularly significant for photovoltaic applications. In the priorart, as the angle of the photovoltaic (PV) device changes with respectto the incoming sunlight, the efficiency correspondingly varies as well,and the prior art PV device panels either must be moved to coincide withthe changing angle of incidence, or lose efficiency. In accordance withthe exemplary embodiments, no such movement of the apparatus 200B, 300B,400B, 500B, 600B, 700B is required, due to the concentrating effect ofthe plurality of lenses 150 with its significantly wider angle ofincidence (or acceptance) when implemented as spherical lenses.

While illustrated using a plurality of substrate particles 120 (to forma corresponding plurality of diodes 155) which are spherical and aplurality of lenses 150 which are also spherical, other shapes and formsof such substrate particles 120 and/or lenses 150, in addition tospherical, are within the scope of the claimed invention. Exemplarypluralities of substrate particles 120 having other shapes, such asfaceted, elliptical or elongated, and irregular, for example, areillustrated and discussed below with reference to FIGS. 26-31. Also forexample, a spherical or other shape may be selected to provide opticalresonance of any trapped light within a diode 155, potentiallyincreasing the amount of time in which the light is within a diode 155and thereby increasing the efficiency of photovoltaic diodes 155. Otheroptically resonant forms or shapes for diodes 155 are also feasible,including cylindrical or rod shapes, toroidal or ring shapes, forexample and without limitation. Similarly, other lens 150 shapes (suchas faceted, elliptical (or oblong) and/or irregular shapes, also forexample and without limitation) are also within the scope of the claimedinvention.

For example, the various pluralities of diodes 155 may also be comprisedof different sized spherical diodes 155, for potential optical resonancecorresponding to different wavelengths of light, and similarly, theplurality of lenses 150 may also be comprised of different sizedspherical and other shaped lenses 150, to create a plurality ofdifferent focal points, mode coupling and diffusion capabilities. Thismay serve to increase the spectral density of the light absorbed oremitted. The various lenses 150 of the plurality of lenses 150 may alsohave different indexes (or indices) of refraction, providing a pluralityof different refractive indexes.

For any of these various applications, such as light emittingapplications, the substrate particles 120 may have any shape or size, inaddition to spherical. For example, diodes 155 may be formed which arefaceted or have other surface textures and shapes, to potentiallyincrease light output, as illustrated in FIGS. 26, 27, 30 and 31. Alsofor example, irregularly shaped diodes 155, as illustrated in FIGS. 30and 31, also may be useful for creating multiple focal points (based onmultiple angles of incidence) and for increasing the comparative orrelative size of the junction 275, to have a bigger target area bothlaterally and vertically.

Not separately illustrated, there may be a plurality of layers of diodes155 and/or lenses 150. For example, a plurality of diodes 155 may bestacked, one on top of another, or side-by side along the width of acavity or channel 105, or may be nested, with larger diodes 155 on alayer beneath smaller diodes 155. Also not separately illustrated, anyselected apparatus 200, 300, 400, 500, 600, 700 may have any selectedmixture of different shaped and/or sized diodes 155 and/or lenses 150.In addition, the plurality of lenses 150 suspended in a polymer (resinor other binder) 165 may have any of various locations with respect tothe remainder of the apparatus 200, 300, 400, 500, 600, 700, includingregularly spaced, randomly spaced, irregularly spaced, abutting, spacedapart, stacked, and so on, with some of this variation illustrated inFIG. 31.

FIG. 23 is a perspective view of an exemplary seventh base 100E with aplurality of first conductors 110, a plurality of diodes 155, aplurality of insulators 135, a plurality of second conductors 140, and aplurality of lenses 150 (suspended in a polymer (resin or other binder)165) having been deposited for an apparatus 300 embodiment in accordancewith the teachings of the present invention. FIG. 24 is across-sectional view (through the 80-80′ plane) of the seventh exemplarybase 100E with a plurality of first conductors 110, a plurality ofdiodes 155, a plurality of insulators 135, a plurality of secondconductors 140, a plurality of third conductors 145, and a plurality oflenses 150 having been deposited for an apparatus 300 embodiment inaccordance with the teachings of the present invention. The apparatus300 differs from the embodiments discussed above insofar as the channels(cavities or grooves) 105 of the base 100E have the form of an off-axisparabola (or paraboloid) 105A, and the ridges (or crests) 115 aresubstantially angled compared to substantially flat ridges (or crests)115 of a base 100 (i.e., at a substantial angle (e.g., between about 15to 60 degrees) to a plane defining or comprising the first or secondsides of the base 100E). FIG. 24 also illustrates use of the thirdconductors 145, as discussed above. A resulting apparatus 300, 300Aand/or 300B otherwise functions substantially the same as any of theother apparatus embodiments discussed herein.

As mentioned above, a potential size range for the plurality ofsubstrate particles 120 and resulting plurality of diodes 155 may be inthe range of about 10-40 or 25-40 (or more) microns, which iscomparatively much smaller than conventional, prior art diodes. As aresult, in accordance with the exemplary embodiments, generally thereare comparatively many diodes 155 in a given area of an apparatus 200,300, 400, 500, 600, 700. Such a comparatively high density of diodes 155has the further result of substantial resiliency and robustness, as thestatistical failure of even a high percentage of the diodes 155nonetheless results in a useable apparatus 200, 300, 400, 500, 600, 700.For example, various devices with different amounts of nonfunctioningdiodes 155 may be “binned’ accordingly. Continuing with the example, anapparatus 200, 300, 400, 500, 600, 700 with fewer functioning diodes 155when implemented as LEDs may simply be binned as a lower output lightingdevice comparable to the light output of a 60 W light bulb, rather thana 100 W light bulb.

Also as mentioned above, following deposition of the plurality of lenses150 suspended within the polymer (resin or other binder) 165, variousprotective coatings may be deposited, also as indicated in the relatedapplications incorporated herein by reference.

FIG. 25 is a perspective view of an exemplary eighth base 100F for anapparatus embodiment in accordance with the teachings of the presentinvention, and differs from those previously discussed insofar as thecavities (channels, trenches or voids) 105 are shaped to besubstantially circular (hemispherical) or elliptical depressions orbores 105B, forming a base 100F (which differs from bases 100-100E, 100Gonly due to the shape of the cavities 105B). A resulting apparatus 200,300, 400, 500, 600 and/or 700 otherwise functions substantially the sameas any of the other apparatus embodiments discussed herein.

FIG. 26 is a perspective view of an exemplary base (100, 100A, 100B,100C, 100D) with a plurality of first conductors 110, a plurality ofsubstantially faceted substrate particles 120 forming correspondingfaceted diodes 155A, a plurality of insulators 135, a plurality ofsecond conductors 140, and a plurality of third conductors 145 havingbeen deposited for an apparatus embodiment in accordance with theteachings of the present invention. FIG. 27 is a cross-sectional view ofthe fifth exemplary base 100D with a plurality of first conductors 110,a plurality of substantially faceted substrate particles 120 formingcorresponding faceted diodes 155A, a plurality of insulators 135, aplurality of second conductors 140 and a plurality of third conductors145 having been deposited for an apparatus embodiment in accordance withthe teachings of the present invention. As mentioned above, FIGS. 26 and27 serve to illustrate another exemplary shape for a plurality of diodes155, as faceted diodes 155A (each of which also has a substantiallycurved, shell-shaped penetration layer or region 255 forming acorresponding pn junction 275), and further illustrate an exemplarypattern for deposition of a plurality of third conductors 145 on orwithin one or more second conductors 140, such as having a substantiallystraight line or having a “ladder” shape (not separately illustrated),for example and without limitation. A resulting apparatus otherwisefunctions substantially the same as any of the other apparatusembodiments discussed herein.

FIG. 28 is a perspective view of an exemplary base (100, 100A, 100B,100C, 100D) with a plurality of first conductors 110, a plurality ofsubstantially elliptical (or oblong) substrate particles 120 formingcorresponding elliptical (or oblong) diodes 155B, a plurality ofinsulators 135, and a plurality of second conductors 140 having beendeposited for another apparatus embodiment in accordance with theteachings of the present invention. FIG. 29 is a cross-sectional view ofthe fifth exemplary base 100D with a plurality of first conductors 110,a plurality of substantially elliptical (or oblong) substrate particles120 forming corresponding elliptical (or oblong) diodes 155B, aplurality of insulators 135, and a plurality of second conductors 145having been deposited for an apparatus embodiment in accordance with theteachings of the present invention. As mentioned above, FIGS. 28 and 29serve to illustrate another exemplary shape for a plurality of diodes155, as substantially elliptical (or oblong) diodes 155B (each of whichalso has a substantially curved, shell-shaped penetration layer orregion 255 forming a corresponding pn junction 275). A resultingapparatus otherwise functions substantially the same as any of the otherapparatus embodiments discussed herein.

FIG. 30 is a perspective view of an exemplary base (100E) with aplurality of first conductors 110, a plurality of substantiallyirregular substrate particles 120 forming corresponding irregular diodes155C, a plurality of insulators 135, a plurality of second conductors140, and a plurality of lenses 150 (suspended in a polymer (resin orother binder) 165) having been deposited for an apparatus 500 embodimentin accordance with the teachings of the present invention. FIG. 31 is across-sectional view of the fifth exemplary base 100E with a pluralityof first conductors, a plurality of substantially irregular substrateparticles 120 forming corresponding irregular diodes 155C, a pluralityof insulators 135, a plurality of second conductors 140, and a pluralityof lenses 150 suspended in a polymer (resin or other binder) 165 havingbeen deposited for an apparatus 500 embodiment in accordance with theteachings of the present invention. As mentioned above, FIGS. 30 and 31serve to illustrate another exemplary shape for a plurality of diodes155, as substantially irregular diodes 155C (each of which also has asubstantially curved, irregular shell-shaped penetration layer or region255 forming a corresponding pn junction 275 (or equivalent)).

FIGS. 30 and 31 further serve to illustrate other exemplary variationsconsidered equivalent and within the scope of the claimed invention,including variations on the relative width of the cavities, channels orgrooves 105 compared to the diodes 155, with the cavities, channels orgrooves 105 illustrated as significantly wider than the diodes 155C.With the comparatively wider cavities, channels or grooves 105, thelocations of the various insulators 135 and second conductors 140 alsovary accordingly, as illustrated, and are coupled to or about the sidesof the diodes 155C, rather than being coupled more toward the upper ortop peripheral portions of the diodes 155C. Also illustrated arepenetration layers or regions 255 having a wide variety of shapes whilenonetheless being substantially shell-shaped, and with the regions 255defining corresponding pn junctions 275 which do not fully extend aboutthe diodes 155C, with a diodes 155C continuing to have a significantportion of its substrate exposed and/or coupled to one or moreinsulators 135 or first conductor(s) 110. Lastly, FIGS. 30 and 31further illustrate various exemplary locations of the lenses 150 withinthe scope of the claimed invention, including without limitationabutting a diode 155C, abutting a portion of the base 100E, andspaced-apart. A resulting apparatus 500, 500A and/or 500B otherwisefunctions substantially the same as any of the other apparatusembodiments discussed herein.

FIG. 32 is a perspective view of a sixth exemplary base 100G with aplurality of first conductors 110, a plurality of substantiallyspherical diodes 155, a plurality of insulators 135, a plurality ofsecond conductors 140, a plurality of third conductors 145, and aplurality of lenses 150 (suspended in a polymer (resin or other binder)165) having been deposited for an apparatus 400 embodiment in accordancewith the teachings of the present invention. FIG. 33 is across-sectional view (through the 71-71′ plane) of the sixth exemplarybase 100G with a plurality of first conductors 110, a plurality ofsubstantially spherical diodes 155, a plurality of insulators 135, aplurality of second conductors 140, a plurality of third conductors 145,and a plurality of lenses 150 (suspended in a polymer (resin or otherbinder) 165) having been deposited for an apparatus 400 embodiment inaccordance with the teachings of the present invention. As mentionedabove, the apparatus 400 embodiment differs from the other apparatusesinsofar as the sixth exemplary base 100G further comprises a pluralityof projections (or supports) 245 within the channels 105 (which may beintegrally formed with the base 100G), a plurality of first conductors110 which have a substantially constant or consistent depth conformingto the shape of the channel 105 and the projections 245, and furthercomprises a plurality of integrally formed conductive vias 285, which inthis case, are distributed randomly within the base 100G. The randomdistribution is further illustrated by one of the first conductors 110not being in contact with a via 285 in the selected or particularcross-section (through the 71-71′ plane), but generally will havecontact with a via 285 at some other point along its length (notseparately illustrated). Also not separately illustrated in FIGS. 32 and33, the base 100G may also comprise any of the additional coatings orlayers (250, 260, 270) discussed above. FIG. 33 also illustrates thatany of the plurality of diodes 155 may have a (variable) gap between itssides and the walls of the channel 105 of the base 100G, which asillustrated has been partially filled in by insulators 135, and variablespacing between and among the lenses 150 and also other apparatuscomponents. A resulting apparatus 400, 400A and/or 400B otherwisefunctions substantially the same as any of the other apparatusembodiments discussed herein.

FIG. 34 is a perspective view of an exemplary base 100 or 100F with afirst conductor 110, a plurality of substantially spherical diodes 155,an insulator 135, a second conductor 140, and a third conductor havingbeen deposited for an apparatus 600 embodiment in accordance with theteachings of the present invention. FIG. 35 is a perspective view of anexemplary base 100 or 100F with a first conductor 110, a plurality ofsubstantially spherical diodes 155, an insulator 135, a second conductor140, a third conductor 145, and a plurality of lenses 150 (suspended ina polymer (resin or other binder) 165) having been deposited for anapparatus 600 embodiment in accordance with the teachings of the presentinvention. FIG. 36 is a cross-sectional view (through the 72-72′ plane)of the exemplary base 100 or 100F with a first conductor 110, aplurality of substantially spherical diodes 155, an insulator 135, asecond conductor 140, a third conductor 145, and a plurality of lenses150 (suspended in a polymer (resin or other binder) 165)) having beendeposited for an apparatus 600 embodiment in accordance with theteachings of the present invention. As mentioned above, the apparatus600 embodiment differs from the other apparatuses insofar as each of thefirst conductor 110, the insulator 135, the second conductor 140 (andalso a third conductor 145) are formed as corresponding single layers,rather than as corresponding pluralities of discrete conductors andinsulators. Not separately illustrated, the base may be and/or includeany of the other features discussed above with respect to bases100-100G, such as conductive vias 280, 285 or a conductive backplane, orthe various coatings or layers 250, 260, 270. As illustrated for thisexemplary apparatus 600, a voltage may be applied (for light emittingapplications) or may be received (for photovoltaic applications) acrossany one or more points or regions of the first conductor 110 and secondconductor 140 (and/or third conductor 145), such as to and from thesides (lateral) of the apparatus 600, or through the other mechanismsmentioned above for any of the other apparatus embodiments (such as whenan apparatus 600 further comprises one or more conductive vias 280, 285and/or a conductive backplane). As illustrated, an optional thirdconductor 145 may be formed as a singular conductive trace, such ashaving a grid pattern over or within the second conductor 140. Asdiscussed above, any of these various layers may be deposited throughany deposition, printing, coating, sputtering, spin casting, etc.processes. A resulting apparatus 600, 600A and/or 600B does not providefor individual row, column, or pixel addressability, but is otherwisefunctions substantially the same as any of the other apparatusembodiments discussed herein.

FIG. 37 is a perspective view of a ninth exemplary base 100H with afirst conductor 110, a first conductor (or conductive) adhesive layer110A, a plurality of substrate particles 120, and one or more insulators135 for an apparatus 700 embodiment in accordance with the teachings ofthe present invention. FIG. 38 is a cross-sectional view (through the73-73′ plane) of the ninth exemplary base 100H with a first conductor110, a first conductor (or conductive) adhesive layer 110A, a pluralityof substrate particles 120, and one or more insulators 135 for anapparatus 700 embodiment in accordance with the teachings of the presentinvention. For this exemplary embodiment, the illustrated base 100H hasa substantially flat overall form factor and has a substantially smoothfirst surface or side (a substantially smooth and substantially flatbase 100H) within a predetermined tolerance (and does not includecavities, channels or grooves 105, e.g., is not reticulated), and afirst conductor 110 is formed as a single, unitary layer, such as aprefabricated aluminum sheet. Depending upon the support provided by thefirst conductor 110, the base 100H may be optionally included, withelectrical insulation of the first conductor provided through othermechanisms, such as a device housing (not separately illustrated). Alsoin this exemplary embodiment, a first conductor (or conductive) adhesivelayer 110A is utilized to adhere a plurality of substrate particles 120to the first conductor 110 and to create ohmic contacts between theplurality of substrate particles 120 and the first conductor 110, andfor example, the first conductor (or conductive) adhesive layer 110A maycomprise an anisotropic conductive binder or polymer or another type ofconductive polymer, resin, or binder discussed above. Followingdeposition of a plurality of substrate particles 120, using any of themethods discussed above, an insulating layer is deposited to forminsulator 135, using any type of insulating or dielectric materialdiscussed above.

FIG. 39 is a perspective view of a ninth exemplary base 100H with afirst conductor 110, a first conductor (or conductive) adhesive layer110A, a plurality of diodes 155 formed using a deposited substrate (orsemiconductor) layer or region 255A over a plurality of substrateparticles 120, an insulator 135, a second conductor 140, and a pluralityof lenses 150 (suspended in a polymer (resin or other binder) 165))having been deposited for an exemplary apparatus 700 embodiment inaccordance with the teachings of the present invention. FIG. 40 is across-sectional view of the ninth exemplary base 100H with a firstconductor 110, a first conductor (or conductive) adhesive layer 110A, aplurality of diodes 155 formed using a deposited substrate (orsemiconductor) layer or region 255A over a plurality of substrateparticles 120, an insulator 135, a second conductor 140, and a pluralityof lenses 150 (suspended in a polymer (resin or other binder) 165))having been deposited for an exemplary apparatus 700 embodiment inaccordance with the teachings of the present invention. As discussedabove with reference to FIG. 15, for such an exemplary embodiment, adiode 155 comprises a layer or region 255A coupled to a substrateparticle 120 to form a junction 275.

As an example, for a plurality of substrate particles 120 comprising asemiconductor having a first majority carrier (e.g., p+ or n+), a layeror region 255A is created which has a second majority carrier (e.g.,correspondingly n+ or p+), also forming junction 275. For semiconductorsubstrate particles 120, the junction 275 is generally a pn (or PN)junction 275, while for organic or polymer substrate particles 120, thejunction 275 may be considered a junction between the organic or polymerlayers utilized to create OLEDs or PLEDs, for example and withoutlimitation. For the illustrated exemplary embodiment 700, as part of adeposition process, such as using plasma deposition or sputtering, forsemiconductor substrate type having a first majority carrier (e.g. p+silicon), a semiconductor material having a second majority carrier(e.g., an n-type dopant, such as a phosphorus-doped silicon) isdeposited over (on top of) a first or upper portion of the plurality ofsubstrate particles 120 and any one or more insulators 135, forming asubstantially continuous, glass-like layer or region 255A, withjunctions 275 formed over the portions of the layer or region 255A incontact with the substrate particles 120. The corresponding depositedsecond majority carrier (n-type) semiconductor material forms acontinuous semiconductor body with each of the substrate particles 120,such as forming a continuous crystal or other bond with the upperportion of a substrate particle 120, forming a deposited layer or region255A which, in this case, is an n-type layer or region 255A whichdefines a corresponding junction 275 (in this case, a pn junction 275)with a first majority carrier (p-type) semiconductor substrate particle120. In the illustrated exemplary embodiment, the corresponding pnjunction 275 is also formed as a “cap” over the substrate particle 120,and is also substantially curved and shell-shaped, such as hemisphericalshell-shaped when the plurality of substrate particles 120 aresubstantially spherical, and also is in sharp contrast to typical priorart diodes having a substantially planar and flat pn junction or asubstantially planar and flat pn junction within a well of asemiconductor substrate. Conversely, a first majority carrier (p-type)layer or region 255A may be formed over a second majority carrier(n-type) semiconductor particle 120, and is considered equivalent andalso within the scope of the present invention. Following deposition ofa layer or region 255A, one or more second conductors 140 (and,optionally, one or more third conductors 145) and a plurality of lenses150 (suspended in a polymer (resin or other binder) 165)) may bedeposited as discussed above, to form an exemplary apparatus 700embodiment.

As mentioned above, and similar to the apparatus 600 embodiment, theapparatus 700 embodiment differs from the other apparatuses insofar aseach of the first conductor 110, first conductor (or conductive)adhesive layer 110A, the insulator 135, the layer or region 255A, thesecond conductor 140 (and also an optional third conductor 145) areformed as corresponding single layers, rather than as correspondingpluralities of discrete conductors and insulators. Not separatelyillustrated, the base may be and/or include any of the other featuresdiscussed above with respect to bases 100-100G, such as conductive vias280, 285 or a conductive backplane, or the various coatings or layers250, 260, 270. As illustrated for this exemplary apparatus 700, avoltage may be applied (for light emitting applications) or may bereceived (for photovoltaic applications) across any one or more pointsor regions of the first conductor 110 and second conductor 140 (and/orthird conductor 145), such as to and from the sides (lateral) of theapparatus 700, or through the other mechanisms mentioned above for anyof the other apparatus embodiments (such as when an apparatus 700further comprises one or more conductive vias 280, 285 and/or aconductive backplane). Not separately illustrated, an optional thirdconductor 145 may be formed as a singular conductive trace, such ashaving a grid pattern over or within the second conductor 140, aspreviously discussed and illustrated. Also as discussed above, any ofthese various layers may be deposited through any deposition, printing,coating, sputtering, spin casting, etc. processes. A resulting apparatus700, 700A and/or 700B does not provide for individual row, column, orpixel addressability, but is otherwise functions substantially the sameas any of the other apparatus embodiments discussed herein.

Those having skill in the art will recognize that any number of firstconductors 110, insulators 135, second conductors 140, and/or thirdconductors 145 may be utilized within the scope of the claimedinvention. In addition, there may be a wide variety of orientations andconfigurations of the plurality of first conductors 110, plurality ofinsulators 135, and the plurality of second conductor(s) 140 (with anyincorporated corresponding and optional one or more third conductors145) for any of the apparatuses 200, 300, 400, 500, in addition to thesubstantially parallel orientations illustrated in FIGS. 1-33. Forexample, the plurality of first conductors 110 and plurality of secondconductor(s) 140 may be perpendicular to each other (defining rows andcolumns), such that their area of overlap may be utilized to define apicture element (“pixel”) and may be separately and independentlyaddressable. When either or both the plurality of first conductors 110and the plurality of second conductor(s) 140 may be implemented asspaced-apart and substantially parallel lines having a predeterminedwidth (both defining rows or both defining columns), they may also beaddressable by row and/or column, such as sequential addressing of onerow after another, for example and without limitation. In addition,either or both the plurality of first conductors 110 and the pluralityof second conductor(s) 140 may be implemented as a layer or sheet asmentioned above.

As indicated above, the plurality of diodes 155 may be configured(through material selection and corresponding doping) to be photovoltaic(PV) diodes 155 or LEDs 155, as examples and without limitation. FIG. 41is a block diagram illustrating a first system embodiment 350 inaccordance with the teachings of the present invention, in which theplurality of diodes 155 are implemented as LEDs, of any type or color.The system 350 comprises an apparatus 200A, 300A, 400A, 500A, 600A, 700Ahaving the plurality of diodes 155 implemented as LEDs, a power source340, and may also include an optional controller 320. When one or morefirst conductors 110 and one or more second conductor(s) 140 (and theoptional one or more third conductors 145) are energized, such asthrough the application of a corresponding voltage (e.g., from powersource 340), energy will be supplied to one or more of the plurality ofLEDs (155), either entirely across the apparatus 600A when theconductors and insulators are each implemented as single layers, or foran apparatus 200A, 300A, 400A, 500A, at the corresponding intersections(overlapping areas) of the energized first conductors 110 and secondconductor(s) 140, which depending upon their orientation andconfiguration, define a pixel, a sheet, or a row/column, for example.Accordingly, by selectively energizing the first conductors 110 andsecond conductor(s) 140 (and/or third conductors 145), the apparatus200A, 300A, 400A, 500A (and/or system 350) provides a pixel-addressable,dynamic display, or a lighting device, or signage, etc. For example, theplurality of first conductors 110 may comprise a corresponding pluralityof rows, with the plurality of transmissive second conductor(s) 140 (andthe optional one or more third conductors 145) comprising acorresponding plurality of columns, with each pixel defined by theintersection or overlapping of a corresponding row and correspondingcolumn. When either or both the plurality of first conductors 110 andthe plurality of second conductor(s) 140 (and/or third conductors 145)may be implemented as a unitary sheet such as in apparatus 600A, alsofor example, energizing of the conductors 110, 140 (and/or 145) willprovide power to substantially all (or most) of the plurality of LEDs(155), such as to provide light emission for a lighting device or astatic display, such as signage.

Continuing to refer to FIG. 41, the apparatus 200A, 300A, 400A, 500A,600A, 700A is coupled through lines or connectors 310 (which may be twoor more corresponding connectors or may also be in the form of a bus,for example) to control bus 315, for coupling to controller (or,equivalently, control logic block) 320, and/or for coupling to a powersource 340, which may be a DC power source (such as a battery or aphotovoltaic cell) or an AC power source (such as household or buildingpower). When the controller 320 is implemented, such as for anaddressable light emitting display system 350 embodiment and/or adynamic light emitting display system 350 embodiment, the controller 320may be utilized to control the energizing of the LEDs (155) (via thevarious pluralities of first conductors 110 and the plurality oftransmissive second conductor(s) 140 (and the optional one or more thirdconductors 145)) as known or becomes known in the electronic arts, andtypically comprises a processor 325, a memory 330, and an input/output(I/O) interface 335. When the controller 320 is not implemented, such asfor various lighting system 350 embodiments (which are typicallynon-addressable and/or a non-dynamic light emitting display system 350embodiments), the system 350 is typically coupled to an electrical orelectronic switch (not separately illustrated), which may comprise anysuitable type of switching arrangement, such as for turning on, off,and/or dimming a lighting system.

A “processor” 325 may be any type of controller or processor, and may beembodied as one or more processors 325, to perform the functionalitydiscussed herein. As the term processor is used herein, a processor 325may include use of a single integrated circuit (“IC”), or may includeuse of a plurality of integrated circuits or other components connected,arranged or grouped together, such as controllers, microprocessors,digital signal processors (“DSPs”), parallel processors, multiple coreprocessors, custom ICs, application specific integrated circuits(“ASICs”), field programmable gate arrays (“FPGAs”), adaptive computingICs, associated memory (such as RAM, DRAM and ROM), and other ICs andcomponents. As a consequence, as used herein, the term processor shouldbe understood to equivalently mean and include a single IC, orarrangement of custom ICs, ASICs, processors, microprocessors,controllers, FPGAs, adaptive computing ICs, or some other grouping ofintegrated circuits which perform the functions discussed below, withassociated memory, such as microprocessor memory or additional RAM,DRAM, SDRAM, SRAM, MRAM, ROM, FLASH, EPROM or E²PROM. A processor (suchas processor 325), with its associated memory, may be adapted orconfigured (via programming, FPGA interconnection, or hard-wiring) toperform the methodology of the invention, such as selective pixeladdressing for a dynamic display embodiment, or row/column addressing,such as for a signage embodiment. For example, the methodology may beprogrammed and stored, in a processor 325 with its associated memory(and/or memory 330) and other equivalent components, as a set of programinstructions or other code (or equivalent configuration or otherprogram) for subsequent execution when the processor is operative (i.e.,powered on and functioning). Equivalently, when the processor 325 mayimplemented in whole or part as FPGAs, custom ICs and/or ASICs, theFPGAs, custom ICs or ASICs also may be designed, configured and/orhard-wired to implement the methodology of the invention. For example,the processor 325 may be implemented as an arrangement of processors,controllers, microprocessors, DSPs and/or ASICs, collectively referredto as a “controller” or “processor”, which are respectively programmed,designed, adapted or configured to implement the methodology of theinvention, in conjunction with a memory 330.

A processor (such as processor 325), with its associated memory, may beconfigured (via programming, FPGA interconnection, or hard-wiring) tocontrol the energizing of (applied voltages to) the various pluralitiesof first conductors 110 and the plurality of transmissive secondconductor(s) 140 (and the optional one or more third conductors 145),for corresponding control over what information is being displayed. Forexample, static or time-varying display information may be programmedand stored, configured and/or hard-wired, in a processor 325 with itsassociated memory (and/or memory 330) and other equivalent components,as a set of program instructions (or equivalent configuration or otherprogram) for subsequent execution when the processor 325 is operative.

The memory 330, which may include a data repository (or database), maybe embodied in any number of forms, including within any computer orother machine-readable data storage medium, memory device or otherstorage or communication device for storage or communication ofinformation, currently known or which becomes available in the future,including, but not limited to, a memory integrated circuit (“IC”), ormemory portion of an integrated circuit (such as the resident memorywithin a processor 325), whether volatile or non-volatile, whetherremovable or non-removable, including without limitation RAM, FLASH,DRAM, SDRAM, SRAM, MRAM, FeRAM, ROM, EPROM or E²PROM, or any other formof memory device, such as a magnetic hard drive, an optical drive, amagnetic disk or tape drive, a hard disk drive, other machine-readablestorage or memory media such as a floppy disk, a CDROM, a CD-RW, digitalversatile disk (DVD) or other optical memory, or any other type ofmemory, storage medium, or data storage apparatus or circuit, which isknown or which becomes known, depending upon the selected embodiment. Inaddition, such computer readable media includes any form ofcommunication media which embodies computer readable instructions, datastructures, program modules or other data in a data signal or modulatedsignal, such as an electromagnetic or optical carrier wave or othertransport mechanism, including any information delivery media, which mayencode data or other information in a signal, wired or wirelessly,including electromagnetic, optical, acoustic, RF or infrared signals,and so on. The memory 330 may be adapted to store various look uptables, parameters, coefficients, other information and data, programsor instructions (of the software of the present invention), and othertypes of tables such as database tables.

As indicated above, the processor 325 is programmed, using software anddata structures of the invention, for example, to perform themethodology of the present invention. As a consequence, the system andmethod of the present invention may be embodied as software whichprovides such programming or other instructions, such as a set ofinstructions and/or metadata embodied within a computer readable medium,discussed above. In addition, metadata may also be utilized to definethe various data structures of a look up table or a database. Suchsoftware may be in the form of source or object code, by way of exampleand without limitation. Source code further may be compiled into someform of instructions or object code (including assembly languageinstructions or configuration information). The software, source code ormetadata of the present invention may be embodied as any type of code,such as C, C++, SystemC, LISA, XML, Java, Brew, SQL and its variations,or any other type of programming language which performs thefunctionality discussed herein, including various hardware definition orhardware modeling languages (e.g., Verilog, VHDL, RTL) and resultingdatabase files (e.g., GDSII). As a consequence, a “construct”, “programconstruct”, “software construct” or “software”, as used equivalentlyherein, means and refers to any programming language, of any kind, withany syntax or signatures, which provides or can be interpreted toprovide the associated functionality or methodology specified (wheninstantiated or loaded into a processor or computer and executed,including the processor 325, for example).

The software, metadata, or other source code of the present inventionand any resulting bit file (object code, database, or look up table) maybe embodied within any tangible storage medium, such as any of thecomputer or other machine-readable data storage media, ascomputer-readable instructions, data structures, program modules orother data, such as discussed above with respect to the memory 330,e.g., a floppy disk, a CDROM, a CD-RW, a DVD, a magnetic hard drive, anoptical drive, or any other type of data storage apparatus or medium, asmentioned above.

The I/O interface 335 may be implemented as known or may become known inthe art, and may include impedance matching capability, voltagetranslation for a low voltage processor to interface with a highervoltage control bus 315 for example, various switching mechanisms (e.g.,transistors) to turn various lines or connectors 310 on or off inresponse to signaling from the processor 325, and/or physical couplingmechanisms. In addition, the I/O interface 335 may also be adapted toreceive and/or transmit signals externally to the system 300, such asthrough hard-wiring or RF signaling, for example, to receive informationin real-time to control a dynamic display, for example.

For example, an exemplary first system embodiment 350 comprises anapparatus 200A, 300A, 400A, 500A, 600A, 700A, in which the plurality ofdiodes 155 are light emitting diodes, and an I/O interface 335 to fitany of the various standard Edison sockets for light bulbs. Continuingwith the example and without limitation, the I/O interface 335 may besized and shaped to conform to one or more of the standardized screwconfigurations, such as the E12, E14, E26, and/or E27 screw basestandards, such as a medium screw base (E26) or a candelabra screw base(E12), and/or the other various standards promulgated by the AmericanNational Standards Institute (“ANSI”) and/or the IlluminatingEngineering Society, also for example. In other exemplary embodiments,the I/O interface 335 may be sized and shaped to conform to a standardfluorescent bulb socket or a two plug base, such as a GU-10 base, alsofor example and without limitation. Such an exemplary first systemembodiment 350 also may be viewed equivalently as another type ofapparatus, particularly when having a form factor compatible forinsertion into an Edison or fluorescent socket, for example and withoutlimitation.

In addition to the controller 320 illustrated in FIG. 41, those havingskill in the art will recognize that there are innumerable equivalentconfigurations, layouts, kinds and types of control circuitry known inthe art, which are within the scope of the present invention.

As indicated above, the plurality of diodes 155 also may be configured(through material selection and corresponding doping) to be photovoltaic(PV) diodes 155. FIG. 42 is a block diagram illustrating a second systemembodiment 375 in accordance with the teachings of the presentinvention, in which the plurality of diodes 155 are implemented asphotovoltaic (PV) diodes 155. The system 375 comprises an apparatus200B, 300B, 400B, 500B, 600B, 700B having the plurality of diodes 155implemented as photovoltaic (PV) diodes 155 and either or both an energystorage device 380, such as a battery, or an interface circuit 385 todeliver power to an energy using apparatus or system or energydistributing apparatus or system, for example, such as a motorizeddevice or an electric utility. (In other exemplary embodiments which donot comprise an interface circuit 385, other circuit configurations maybe utilized to provide energy or power directly to such an energy usingapparatus or system or energy distributing apparatus or system.) Withinthe system 375, the one or more first conductors 110 of an apparatus200B, 300B, 400B, 500B, 600B, 700B are coupled to form a first terminal(such as a negative or positive terminal), and the one or more secondconductor(s) 140 (and/or third conductors 145) of the apparatus 200B,300B, 400B, 500B, 600B, 700B are coupled to form a second terminal (suchas a correspondingly positive or negative terminal), which are thencouplable to lines or connectors 310 for connection to either or both anenergy storage device 380 or an interface circuit 385. When light (suchas sunlight) is incident upon the plurality of spherical lenses 150 ofan apparatus 200B, 300B, 400B, 500B, 600B, 700B (from any of a widerange of angles, as discussed above), the light is concentrated on oneof more photovoltaic (PV) diodes 155 which, in turn, convert theincident photons to electron-hole pairs, resulting in an output voltagegenerated across the first and second terminals, and output to either orboth an energy storage device 380 or an interface circuit 385.

FIG. 43 is a flow chart illustrating a method embodiment in accordancewith the teachings of the present invention, for forming or otherwisemanufacturing an apparatus 200, 300, 400, 500, 600, 700, and provides auseful summary. Beginning with start step 702, the method deposits aplurality of first conductors (110), typically within a correspondingplurality of channels (cavities, channels or grooves 105) of a base(100-100G), such as by printing a conductive ink or polymer orsputtering or coating the base (100-100G) with one or more metals,followed by curing or partially curing the conductive ink or polymer, orpotentially removing a deposited metal from the various ridges or crests115, depending upon the implementation, step 705. Also depending uponthe implementation, additional steps may be utilized to form a base 100,such as fabrication of the base and/or cavities, channels or grooves105, the addition of a reflective or refractive coating 270, or areflector, refractor or mirror 250 (e.g., an optical grating, a Braggreflector) with a coating (260), or the addition of a conductivebackplane (290) and vias (280, 285). A plurality of substrate particles120, having typically been suspended in a binder or other compound ormixture (e.g., suspended in a volatile solvent or reactive agent), suchas to form a substrate (e.g., semiconductor) particle ink or suspension,are then deposited over the plurality of first conductors, typically inthe corresponding channels 105, step 710, also typically throughprinting or coating, to form an ohmic contact between the plurality ofsubstrate particles 120 and the one or more first conductors (which mayalso involve various chemical reactions, compression and/or heating, forexample and without limitation).

One or more dopants (also referred to equivalently as dopant compounds)or additional organic light emitting layers for OLED implementations (asdiscussed above) are deposited on or over the plurality of substrateparticles 120, also typically through printing or coating, which arethen heated, energized or otherwise cured as needed, such as throughlaser or thermal annealing or alloying, to form a correspondingplurality of diodes 155, step 715, such as photovoltaic (PV) diodes,LEDs, or OLEDs. An insulating material, such as a particulate dielectriccompound suspended in a polymer or binder, is then deposited on or overcorresponding first portions of the plurality of diodes 155, such asabout the periphery of the diodes 155 (and cured or heated), step 720,to form one or more insulators 135. Next, one or more second conductors(which may or may not be optically transmissive) are then deposited tocorresponding second portions of the plurality of diodes 155, such asover the insulators 135 and about the periphery of the diodes 155, andcured (or heated), step 725, also to form ohmic contacts between the oneor more second conductors (140) and the plurality of plurality of diodes155. In exemplary embodiments, such as for an addressable display, theplurality of (transmissive) second conductors 140 are orientedsubstantially perpendicular to the plurality of first conductors 110.Optionally, one or more third conductors (145) are then deposited (andcured or heated) over the corresponding one or more (transmissive)second conductors, step 730.

As another option, in step 735, testing may be performed, withnon-functioning or otherwise defective diodes 155 removed or disabled.For example, for PV diodes, the surface (first side) of the partiallycompleted apparatus may be scanned with a laser or other light sourceand, when a region (or individual diode 155) does not provide theexpected electrical response, it may be removed using a high intensitylaser or other removal technique. Also for example, for light emittingdiodes which have been powered on, the surface (first side) may bescanned with a photosensor, and, when a region (or individual diode 155)does not provide the expected light output and/or draws excessivecurrent (i.e., current in excess of a predetermined amount), it also maybe removed using a high intensity laser or other removal technique.Depending upon the implementation, such as depending upon hownon-functioning or defective diodes 155 are removed, the testing step735 may be performed instead after steps 740 or 745 discussed below. Aplurality of lenses (150), also typically having been suspended in apolymer, a binder, or other compound or mixture to form a lensing orlens particle ink or suspension, are then place or deposited over theplurality of spherical diodes 155, step 740, also typically throughprinting, or a preformed lens panel comprising a plurality of lenses 150suspended in a polymer is attached to the first side of the partiallycompleted apparatus (such as through a lamination process), followed byany optional deposition (such as through printing) of protectivecoatings (and/or selected colors), step 745, and the method may end,return step 750.

Although the invention has been described with respect to specificembodiments thereof, these embodiments are merely illustrative and notrestrictive of the invention. In the description herein, numerousspecific details are provided, such as examples of electroniccomponents, electronic and structural connections, materials, andstructural variations, to provide a thorough understanding ofembodiments of the present invention. One skilled in the relevant artwill recognize, however, that an embodiment of the invention can bepracticed without one or more of the specific details, or with otherapparatus, systems, assemblies, components, materials, parts, etc. Inother instances, well-known structures, materials, or operations are notspecifically shown or described in detail to avoid obscuring aspects ofembodiments of the present invention. One having skill in the art willfurther recognize that additional or equivalent method steps may beutilized, or may be combined with other steps, or may be performed indifferent orders, any and all of which are within the scope of theclaimed invention. In addition, the various Figures are not drawn toscale and should not be regarded as limiting.

Reference throughout this specification to “one embodiment”, “anembodiment”, or a specific “embodiment” means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention and notnecessarily in all embodiments, and further, are not necessarilyreferring to the same embodiment. Furthermore, the particular features,structures, or characteristics of any specific embodiment of the presentinvention may be combined in any suitable manner and in any suitablecombination with one or more other embodiments, including the use ofselected features without corresponding use of other features. Inaddition, many modifications may be made to adapt a particularapplication, situation or material to the essential scope and spirit ofthe present invention. It is to be understood that other variations andmodifications of the embodiments of the present invention described andillustrated herein are possible in light of the teachings herein and areto be considered part of the spirit and scope of the present invention.

It will also be appreciated that one or more of the elements depicted inthe Figures can also be implemented in a more separate or integratedmanner, or even removed or rendered inoperable in certain cases, as maybe useful in accordance with a particular application. Integrally formedcombinations of components are also within the scope of the invention,particularly for embodiments in which a separation or combination ofdiscrete components is unclear or indiscernible. In addition, use of theterm “coupled” herein, including in its various forms such as “coupling”or “couplable”, means and includes any direct or indirect electrical,structural or magnetic coupling, connection or attachment, or adaptationor capability for such a direct or indirect electrical, structural ormagnetic coupling, connection or attachment, including integrally formedcomponents and components which are coupled via or through anothercomponent.

As used herein for purposes of the present invention, the term “LED” andits plural form “LEDs” should be understood to include anyelectroluminescent diode or other type of carrier injection- orjunction-based system which is capable of generating radiation inresponse to an electrical signal, including without limitation, varioussemiconductor- or carbon-based structures which emit light in responseto a current or voltage, light emitting polymers, organic LEDs, and soon, including within the visible spectrum, or other spectra such asultraviolet or infrared, of any bandwidth, or of any color or colortemperature. Also as used herein for purposes of the present invention,the term “photovoltaic diode” (or PV) and its plural form “PVs” shouldbe understood to include any photovoltaic diode or other type of carrierinjection- or junction-based system which is capable of generating anelectrical signal (such as a voltage) in response to incident energy(such as light or other electromagnetic waves) including withoutlimitation, various semiconductor- or carbon-based structures whichgenerate of provide an electrical signal in response to light, includingwithin the visible spectrum, or other spectra such as ultraviolet orinfrared, of any bandwidth or spectrum.

Furthermore, any signal arrows in the drawings/Figures should beconsidered only exemplary, and not limiting, unless otherwisespecifically noted. Combinations of components of steps will also beconsidered within the scope of the present invention, particularly wherethe ability to separate or combine is unclear or foreseeable. Thedisjunctive term “or”, as used herein and throughout the claims thatfollow, is generally intended to mean “and/or”, having both conjunctiveand disjunctive meanings (and is not confined to an “exclusive or”meaning), unless otherwise indicated. As used in the description hereinand throughout the claims that follow, “a”, “an”, and “the” includeplural references unless the context clearly dictates otherwise. Also asused in the description herein and throughout the claims that follow,the meaning of “in” includes “in” and “on” unless the context clearlydictates otherwise.

The foregoing description of illustrated embodiments of the presentinvention, including what is described in the summary or in theabstract, is not intended to be exhaustive or to limit the invention tothe precise forms disclosed herein. From the foregoing, it will beobserved that numerous variations, modifications and substitutions areintended and may be effected without departing from the spirit and scopeof the novel concept of the invention. It is to be understood that nolimitation with respect to the specific methods and apparatusillustrated herein is intended or should be inferred. It is, of course,intended to cover by the appended claims all such modifications as fallwithin the scope of the claims.

1. An apparatus, comprising: a base comprising a plurality ofspaced-apart channels; a plurality of first conductors coupled to thebase, each first conductor in a corresponding channel of the pluralityof spaced-apart channels; a plurality of substantially spherical diodescoupled to the plurality of first conductors, wherein about fifteenpercent to fifty-five percent of a surface of each diode ofsubstantially all of the plurality of substantially spherical diodes hasa penetration layer or region having a first majority carrier or dopantand the remaining diode substrate has a second majority carrier ordopant; a plurality of second conductors coupled to the plurality ofsubstantially spherical diodes; and a plurality of lenses having atleast a first index of refraction, the plurality of lenses suspended ina first polymer having at least a second, different index of refraction.2. The apparatus of claim 1, wherein substantially all of the pluralityof substantially spherical diodes have a substantially hemisphericalshell pn junction.
 3. The apparatus of claim 1, wherein each diode ofthe plurality of substantially spherical diodes comprises a first parthaving a substantially hemispherical shell or capped pn junction and asecond part having at least partially spheroid substrate.
 4. Theapparatus of claim 1, wherein the plurality of lenses are substantiallyspherical and a ratio of a mean diameter of the plurality of lenses to amean diameter of the plurality of substantially spherical diodes issubstantially about five to one (5:1).
 5. The apparatus of claim 1,wherein the plurality of lenses are substantially spherical and a ratioof a mean diameter of the plurality of lenses to a mean diameter of theplurality of substantially spherical diodes is between about ten to one(10:1) and two to one (2:1).
 6. The apparatus of claim 5, wherein thecomparative size or spacing of the plurality of lenses provide a modecoupling to the plurality of substantially spherical diodes.
 7. Theapparatus of claim 1, wherein a mean diameter of the plurality ofsubstantially spherical diodes is greater than about twenty (20) micronsand less than about forty (40) microns.
 8. The apparatus of claim 1,wherein the plurality of substantially spherical diodes are selectedfrom the group consisting of: semiconductor light emitting diodes,organic light emitting diodes, encapsulated organic light emittingdiodes, polymer light emitting diodes, photovoltaic diodes, and mixturesthereof.
 9. The apparatus of claim 1, wherein the plurality ofsubstantially spherical diodes comprise a semiconductor selected fromthe group consisting of: gallium nitride, gallium arsenide, silicon, andmixtures thereof.
 10. The apparatus of claim 1, further comprising: aplurality of third conductors coupled to the plurality of secondconductors.
 11. The apparatus of claim 1, wherein the base furthercomprises a reflector or a refractor.
 12. The apparatus of claim 1,wherein the base further comprises a Bragg reflector or a reflectiveplastic or polyester coating.
 13. The apparatus of claim 1, furthercomprising a plurality of conductive vias extending between a first sideand a second side of the base and coupled at the first side to theplurality of first conductors.
 14. The apparatus of claim 13, whereinthe base further comprises a conductive backplane coupled to theplurality of conductive vias and coupled to or integrated with thesecond side of the base.
 15. The apparatus of claim 13, wherein theplurality of conductive vias comprise a plurality of substantiallyrandomly distributed, substantially spherical conductors.
 16. Theapparatus of claim 1, further comprising: a plurality of insulatorscorrespondingly coupled to each of the plurality of substantiallyspherical diodes and comprising a plurality of inorganic dielectricparticles suspended with a photoinitiator compound in a second polymeror resin.
 17. The apparatus of claim 1, further comprising: a pluralityof insulators correspondingly coupled to each of the plurality ofsubstantially spherical diodes and comprising a photoinitiator compoundand a second polymer or resin.
 18. The apparatus of claim 1, wherein thebase has a substantially flat overall form factor with or withoutsurface features and has a thickness of less than about two millimeters.19. The apparatus of claim 1, wherein the base comprises at least one:material selected from the group consisting of: paper, coated paper,plastic coated paper, embossed paper, fiber paper, cardboard, posterpaper, poster board, wood, plastic, rubber, fabric, glass, ceramic, andmixtures thereof.
 20. The apparatus of claim 1, wherein the plurality ofspaced-apart channels are substantially parallel.
 21. The apparatus ofclaim 1, wherein the plurality of spaced-apart channels are at leastpartially hemispherically-shaped and are disposed in an array.
 22. Theapparatus of claim 1, wherein the plurality of spaced-apart channels areat least partially parabolic.
 23. The apparatus of claim 22, wherein thebase further comprises a plurality of angled ridges.
 24. The apparatusof claim 1, wherein the plurality of spaced-apart channels furthercomprise a plurality of integrally formed projections or supports. 25.The apparatus of claim 24, wherein the plurality of first conductors arecoupled to the plurality of integrally formed projections or supportswithin the plurality of spaced-apart channels and the plurality ofsubstantially spherical diodes are alloyed, or annealed, or chemicallycoupled to the plurality of first conductors.
 26. The apparatus of claim1, wherein the plurality of first conductors comprise a cured conductiveink or a cured conductive polymer.
 27. The apparatus of claim 1, whereinthe plurality of first conductors comprise at least one conductor, in acured form, selected from the group consisting of: a silver conductiveink, a copper conductive ink, a gold conductive ink, an aluminumconductive ink, a tin conductive ink, a carbon conductive ink, a carbonnanotube polymer, a conductive polymer, and mixtures thereof.
 28. Theapparatus of claim 1, wherein the plurality of first conductorssubstantially comprise a sputtered, coated, vapor deposited orelectroplated metal, metal alloy, or combination of metals.
 29. Theapparatus of claim 28, wherein the metal, metal alloy, or combination ofmetals comprise at least one a metal selected from the group consistingof: aluminum, copper, silver, nickel, gold, and mixtures thereof. 30.The apparatus of claim 1, wherein the plurality of second conductorscomprise an optically transmissive conductor or conductive compoundsuspended in a polymer, resin or other media.
 31. The apparatus of claim30, wherein the plurality of second conductors comprise at least onematerial or compound, suspended in a polymer, resin or other media, thematerial or compound selected from the group consisting of: carbonnanotubes, antimony tin oxide, indium tin oxide,polyethylene-dioxithiophene, and mixtures thereof.
 32. The apparatus ofclaim 1, wherein the plurality of lenses comprise borosilicate glass orpolystyrene latex.
 33. The apparatus of claim 1, wherein the pluralityof substantially spherical diodes are annealed or alloyed to or withinthe plurality of first conductors.
 34. The apparatus of claim 1, whereinthe plurality of substantially spherical diodes are chemically coupledto or within the plurality of first conductors.
 35. The apparatus ofclaim 1, further comprising: an interface for insertion into astandardized lighting socket.
 36. The apparatus of claim 1, furthercomprising: an interface compatible with an E12, E14, E26, E27, or GU-10lighting standard.
 37. The apparatus of claim 1, further comprising: aninterface for insertion into a standard Edison-type lighting socket. 38.The apparatus of claim 1, further comprising: an interface for insertioninto a standard fluorescent-type lighting socket.
 39. The apparatus ofclaim 1, wherein the apparatus is flexible, or foldable, or creasable.40. An apparatus, comprising: a base; at least one first conductorcoupled to the base; a plurality of substantially spherical diodescoupled to the at least one first conductor, wherein about fifteenpercent to fifty-five percent of a surface of each diode ofsubstantially all of the plurality of substantially spherical diodes hasa penetration layer or region having a first majority carrier or dopantand the remaining diode substrate has a second majority carrier ordopant; at least one second conductor coupled to the plurality ofsubstantially spherical diodes; and a plurality of lenses suspended in afirst polymer and coupled to the plurality of substantially sphericaldiodes.
 41. The apparatus of claim 40, wherein the plurality of lensesare substantially spherical and have at least a first index ofrefraction and the first polymer has at least a second, different indexof refraction.
 42. The apparatus of claim 40, wherein the plurality oflenses are substantially spherical and a ratio of a mean diameter of theplurality of lenses to a mean diameter of the plurality of substantiallyspherical diodes is between about ten to one (10:1) and two to one(2:1).
 43. The apparatus of claim 40, wherein a mean diameter of theplurality of substantially spherical diodes is greater than about twenty(20) microns and less than about forty (40) microns.
 44. The apparatusof claim 40, wherein the plurality of substantially spherical diodes areselected from the group consisting of: semiconductor light emittingdiodes, organic light emitting diodes, encapsulated organic lightemitting diodes, polymer light emitting diodes, photovoltaic diodes, andmixtures thereof.
 45. The apparatus of claim 40, wherein the pluralityof substantially spherical diodes comprise a semiconductor selected fromthe group consisting of: gallium nitride, gallium arsenide, silicon, andmixtures thereof.
 46. The apparatus of claim 40, further comprising: atleast one third conductor coupled to the at least one second conductor.47. The apparatus of claim 40, wherein the base further comprises areflector or a refractor.
 48. The apparatus of claim 40, furthercomprising at least one conductive via extending between a first sideand a second side of the base and coupled at the first side to the atleast one first conductor.
 49. The apparatus of claim 48, wherein thebase further comprises a conductive backplane coupled to the at leastone conductive via and coupled to or integrated with the second side ofthe base.
 50. The apparatus of claim 40, further comprising: at leastone insulator coupled to the plurality of substantially spherical diodesand comprising a plurality of inorganic dielectric particles suspendedwith a photoinitiator compound in a second polymer or resin.
 51. Theapparatus of claim 40, wherein the base has a substantially flat overallform factor with or without surface features and has a thickness of lessthan about two millimeters.
 52. The apparatus of claim 40, wherein thebase comprises at least one material selected from the group consistingof: paper, coated paper, plastic coated paper, embossed paper, fiberpaper, cardboard, poster paper, poster board, wood, plastic, rubber,fabric, glass, ceramic, and mixtures thereof.
 53. The apparatus of claim40, wherein the at least one first conductor comprises a curedconductive ink or a cured conductive polymer.
 54. The apparatus of claim40, wherein the at least one first conductor comprises a sputtered,coated, vapor deposited or electroplated metal, metal alloy, orcombination of metals.
 55. The apparatus of claim 40, wherein the atleast one second conductor comprises an optically transmissive conductoror conductive compound suspended in a polymer, resin or other media. 56.The apparatus of claim 40, wherein the plurality of substantiallyspherical diodes are annealed, or alloyed, or chemically coupled to orwithin the at least one first conductor.
 57. The apparatus of claim 40,wherein the plurality of lenses comprise borosilicate glass orpolystyrene latex.
 58. The apparatus of claim 40, further comprising: aninterface for insertion into a standardized lighting socket.
 59. Theapparatus of claim 40, further comprising: an interface compatible withan E12, E14, E26, E27, or GU-10 lighting standard.
 60. The apparatus ofclaim 40, further comprising: an interface for insertion into a standardEdison-type lighting socket.
 61. The apparatus of claim 40, furthercomprising: an interface for insertion into a standard fluorescent-typelighting socket.
 62. The apparatus of claim 40, wherein the apparatus isflexible, or foldable, or creasable.
 63. An apparatus, comprising: abase having a substantially flat overall form factor with or withoutsurface features and having a thickness of less than about twomillimeters; at least one first conductor coupled to the base; aplurality of substantially optically resonant diodes coupled to the atleast one first conductor; at least one second conductor coupled to theplurality of substantially optically resonant diodes; and a plurality oflenses suspended in a first polymer and coupled to the plurality ofsubstantially optically resonant diodes, the plurality of lenses havingat least a first index of refraction and the first polymer having atleast a second, different index of refraction.
 64. The apparatus ofclaim 63, wherein the plurality of substantially optically resonantdiodes are selected from the group consisting of: substantiallyspherical diodes, substantially toroidal diodes, substantiallycylindrical diodes, and mixtures thereof.
 65. The apparatus of claim 63,wherein about fifteen percent to fifty-five percent of a surface of eachdiode of substantially all of the plurality of substantially opticallyresonant diodes has a penetration layer or region having a firstmajority carrier or dopant and the remaining diode substrate has asecond majority carrier or dopant.
 66. The apparatus of claim 63,wherein the comparative size or spacing of the plurality of lensesprovide a mode coupling to the plurality of substantially opticallyresonant diodes.
 67. The apparatus of claim 63, wherein the plurality oflenses are selected from the group consisting of: substantiallyspherical, substantially hemispherical, substantially faceted,substantially elliptical, substantially oblong, substantially cubic,substantially prismatic, substantially trapezoidal, substantiallytriangular, substantially pyramidal, and mixtures thereof.
 68. Theapparatus of claim 63, wherein a mean diameter or length of theplurality of substantially optically resonant diodes is greater thanabout twenty (20) microns and less than about forty (40) microns. 69.The apparatus of claim 63, wherein the plurality of substantiallyoptically resonant diodes are selected from the group consisting of:semiconductor light emitting diodes, organic light emitting diodes,encapsulated organic light emitting diodes, polymer light emittingdiodes, photovoltaic diodes, and mixtures thereof.
 70. The apparatus ofclaim 63, wherein the plurality of substantially optically resonantdiodes comprise a semiconductor selected from the group consisting of:gallium nitride, gallium arsenide, silicon, and mixtures thereof. 71.The apparatus of claim 63, further comprising at least one conductivevia extending between a first side and a second side of the base andcoupled at the first side to the at least one first conductor.
 72. Theapparatus of claim 63, wherein the base further comprises a conductivebackplane coupled to the at least one conductive via and coupled to orintegrated with the second side of the base.
 73. The apparatus of claim63, further comprising: at least one insulator coupled to the pluralityof substantially optically resonant diodes and comprising a plurality ofinorganic dielectric particles suspended with a photoinitiator compoundin a second polymer or resin.
 74. The apparatus of claim 63, wherein thebase comprises at least one material selected from the group consistingof: paper, coated paper, plastic coated paper, embossed paper, fiberpaper, cardboard, poster paper, poster board, wood, plastic, rubber,fabric, glass, ceramic, and mixtures thereof.
 75. The apparatus of claim63, wherein the at least one first conductor comprises at least oneconductor selected from the group consisting of: a cured conductive ink,a cured conductive polymer, a metal, a metal alloy, a combination ofmetals, and mixtures thereof.
 76. The apparatus of claim 63, wherein theat least one second conductor comprises an optically transmissiveconductor or conductive compound suspended in a polymer, resin or othermedia.
 77. The apparatus of claim 63, wherein the plurality ofsubstantially optically resonant diodes are annealed, or alloyed, orchemically coupled to or within the at least one first conductor. 78.The apparatus of claim 63, wherein the plurality of lenses compriseborosilicate glass or polystyrene latex.
 79. The apparatus of claim 63,further comprising: an interface for insertion into a standardizedlighting socket.
 80. The apparatus of claim 63, further comprising: aninterface compatible with an E12, E14, E26, E27, or GU-10 lightingstandard.
 81. The apparatus of claim 63, further comprising: aninterface for insertion into a standard Edison-type lighting socket. 82.The apparatus of claim 63, further comprising: an interface forinsertion into a standard fluorescent-type lighting socket.
 83. Theapparatus of claim 63, wherein the apparatus is flexible, or foldable,or creasable.
 84. A system, comprising: an interface for insertion intoa standardized lighting socket; a base; at least one first conductorcoupled to the base; a plurality of substantially spherical diodescoupled to the at least one first conductor, the plurality ofsubstantially spherical diodes having a mean diameter greater than abouttwenty (20) microns and less than about forty (40) microns; at least oneinsulator coupled to the plurality of substantially spherical diodes; atleast one second conductor coupled to the plurality of substantiallyspherical diodes; and a plurality of substantially spherical lensessuspended in a polymer and coupled to the plurality of substantiallyspherical diodes, the plurality of substantially spherical lenses havingat least a first index of refraction and the polymer having at least asecond, different index of refraction, wherein a ratio of a meandiameter of the plurality of substantially spherical lenses to the meandiameter of the plurality of substantially spherical diodes is betweenabout ten to one (10:1) and two to one (2:1).
 85. An apparatus,comprising: a base having a plurality of spaced-apart channels, eachchannel of the plurality of spaced-apart channels comprising a pluralityof integrally formed projections; a conductive backplane coupled to orintegrally formed with the base; a plurality of conductive vias withinthe base and coupled to the conductive backplane; at least one firstconductor coupled to the plurality of conductive vias and to theintegrally formed projections; a plurality of substantially sphericaldiodes coupled to the at least one first conductor, about fifteenpercent to fifty-five percent of a surface of each diode ofsubstantially all of the plurality of substantially spherical diodes hasa penetration layer or region having a first majority carrier or dopantand the remaining diode substrate has a second majority carrier ordopant; at least one second conductor coupled to the plurality ofsubstantially spherical diodes; and a plurality of substantiallyspherical lenses suspended in a polymer and coupled to the plurality ofsubstantially spherical diodes.